22-04-2025

Truck rack process optimization: Unlocking efficiency without capital investment

In refinery operations, process effectiveness is not solely a matter of procedures. It hinges on a critical balance between three pillars: the process itself, the system that supports and measures it, and the behavior of the individuals who execute it. At Trindent Consulting, this triad forms the foundation of our performance consulting methodology, an approach that has consistently delivered substantial value across complex organizations, including oil refineries.

One illustrative example is our work optimizing Truck Rack operations, a process often considered routine within refinery workflows. Despite its relative simplicity, it represents a significant opportunity for operational and financial improvement when approached with a comprehensive and structured methodology.

A Simplified Process, a Significant Opportunity
Truck Racks are used to blend refined gasoline types—such as 83 ON and 91 ON—according to well-established recipes before distribution. The underlying calculations are straightforward, and measurement systems are typically in place to ensure accurate blending.

However, our experience has shown that even within this controlled environment, inefficiencies can persist. Octane give-away, for example, is a common and costly issue. Trindent has repeatedly demonstrated that it is possible to reduce this quality giveaway significantly—without the need for capital expenditure—by optimizing how blending is managed and monitored.

An Integrated Approach to Optimization
Our success in this domain is driven by a systematic review of the process, the performance management system, and employee behavior. By identifying deviations from best practices and leveraging our proprietary benchmarking tools, we develop targeted, client-specific solutions.

This integrated approach enhances accuracy in blending and quality control, reduces the risk of failed recipes, and minimizes costly re-blend cycles. Just as importantly, it strengthens the refinery’s ability to consistently deliver high-quality products to end customers, thereby reducing operational risk and improving overall customer satisfaction.

This case underscores a key insight: significant performance gains can be achieved without capital investment. Even seemingly simple processes can yield meaningful returns when evaluated through the lens of performance consulting.

Trindent Consulting continues to help refineries identify and unlock these hidden opportunities—enhancing margins, ensuring operational stability, and driving best-in-class performance across the value chain.

Without capital investment, we create actionable ways to sustainably increase refinery margins by 2-3%. Contact us for a complimentary assessment, to help solve your complex business issues. We are here to Make It Happen™.