Reverse Engineering That Goes Beyond the Original

Expert Reverse Engineering Solutions | Atiyeh Sazan Negin Faraz

What is reverse Engineering?

When you have a machine or production line that works and you need another one just like it, reverse engineering is the answer.

At Atiyeh Sazan Negin Faraz, we go beyond simply copying what already exists. We study the original, rebuild it with precision, and look for every opportunity to make it better.

How It Works

We begin with a careful, hands-on examination of your original sample. From there, our engineers produce everything needed to reconstruct it from scratch:

• Complete manufacturing and assembly drawings
• Full installation documentation
• Detailed parts lists and machinery specifications
• In-depth analysis of system performance and component interaction

More Than Replication

Our engineering team doesn’t stop at duplication. We use each project as an opportunity to evaluate the original design and identify areas for improvement. Depending on your needs, this can include:

• Higher efficiency : getting more output from the same input
• Lower energy consumption : reducing operating costs over time
• Improved safety : meeting modern standards and reducing risk
• Less component wear : extending the working life of critical parts
• Easier maintenance : simplifying upkeep and reducing downtime

Built Better Than the Original

If you want to upgrade while you replicate, our team can implement engineering modifications directly into the build process. The result is a machine that matches your original in appearance and function , but performs at a higher level in quality, reliability, and long-term productivity.

Our Reverse Engineering Services

At Atiyeh Sazan Negin Faraz, we offer a full range of reverse engineering services — from initial inspection through to final replication and optimization.

• Sample Inspection and Analysis : A thorough examination of the original machine or system to capture every functional and structural detail
• Manufacturing and Assembly Drawings : Precise, ready-to-use technical drawings developed to exact specifications
• Technical Specifications and Parts Lists : Complete documentation of components, materials, and machinery requirements
• High-Accuracy Replication : Faithful reconstruction of machines or production lines, built to perform like the original
• Engineering Optimization Proposals : Expert recommendations for improving performance, efficiency, and reliability beyond the original design

Types of Reverse Engineering We Cover

Hardware Reverse Engineering

Analysis of physical components, circuits, and materials : ideal for mechanical and electronic systems that need to be accurately reproduced or improved.

Software Reverse Engineering

Examination of source codes, communication protocols, and algorithms : used to understand, document, or rebuild software-driven systems.

Process Reverse Engineering

Study of production procedures and supply chain operations:  helping clients replicate or refine entire manufacturing workflows.

Here’s the website-ready version:

Key Stages in the Reverse Engineering Process

Every successful reverse engineering project follows a structured path — from the first look at the original sample to a fully validated final product.

1. Identification & Data Collection
   We start by gathering all available product specifications, technical information, and existing documentation to build a complete picture of what we’re working with.
2. Analysis & Decomposition
   Components are carefully disassembled and examined, giving our engineers a clear understanding of how each part functions and contributes to the overall system.
3. Modeling & Documentation
   Using the insights gained, we prepare detailed engineering drawings, technical diagrams, and precise 3D models that form the foundation for reconstruction.
4. Reconstruction & Implementation
   With documentation in hand, we move to building prototypes and developing the required systems or software — bringing the design back to life.
5. Validation & Testing
   The reconstructed product is rigorously compared against the original sample. Any gaps or discrepancies are identified and resolved before final delivery.

Why Production Process Optimization Matters

Replicating a machine is one thing, making it perform better is another. Optimizing the production process delivers real, measurable benefits:

• Greater productivity and operational efficiency
• Lower costs across raw materials, energy, and labor
• Higher quality in the final product
• Shorter production lead times
• A safer, more satisfying workplace for employees

How Reverse Engineering Drives Process Improvement

Reverse engineering isn’t just about copying what exists , it’s one of the most powerful tools available for understanding and improving how things are made.

Uncovering weaknesses in current systems
By analyzing a well-functioning product, our engineers can identify hidden problems in an existing production line before they become costly issues.

Clarifying technical requirements
Breaking down a product’s components and behavior reveals exactly what machinery, materials, and manufacturing tolerances are needed, removing guesswork from the process.

Improving Design for Manufacturability (DFM)
Understanding how an efficient product is built allows engineers to refine designs so they’re easier and less expensive to manufacture at scale.

Discovering better technologies and techniques
The analysis process often surfaces innovative production methods that can be adopted into existing manufacturing lines, keeping operations current and competitive.

Reducing material and energy waste
A detailed product study frequently points to practical strategies for cutting waste and lowering energy consumption without sacrificing performance.

Raising quality standards
Studying a reverse-engineered product gives teams the insight needed to define more accurate, effective quality control criteria , elevating the entire production standard.

A Strategic Tool for Innovation

Reverse engineering is more than a technical service — it’s a driver of continuous improvement in modern manufacturing. By combining deep reverse engineering expertise with sound production management principles, Atiyeh Sazan Negin Faraz is equipped to design and manufacture high-quality products with exceptional precision, fully aligned with what each client needs and expects.

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Ammonium Sulfate Production Line (Fertilizer Grade)

Ammonium sulfate ((NH₄)₂SO₄) is an inorganic salt with numerous commercial applications. Its most common use is as a soil-conditioning fertilizer, as it contains approximately 21% nitrogen (w/w) and 24% sulfur (w/w), making it an effective source of essential plant nutrients.

Production of Granular and Crystalline Ammonium Sulfate Using Advanced Industrial Technologies

Ammonium sulfate is one of the most important nitrogen-sulfur fertilizers used worldwide. It is extensively applied in agriculture, chemical industries, and even water treatment processes. In addition to supplying nitrogen required for plant growth, it increases sulfur content in the soil and improves nutrient uptake efficiency.

Depending on the intended application and market requirements, ammonium sulfate can be produced in either granular or crystalline form, each offering distinct characteristics and advantages.

Granular Ammonium Sulfate Production Technology (Pipe Reactor–Granulator Process)

The production of granular ammonium sulfate utilizes the advanced Pipe Reactor–Granulator process. This technology is recognized as one of the most precise and efficient production methods available, enabling controlled reaction between liquid ammonia (NH₃) and sulfuric acid (H₂SO₄) with minimal energy consumption and raw material losses.

In this system, the raw materials are stored in dedicated storage tanks and delivered through an integrated network of industrial pipelines, pumps, and control valves into a pipe reactor at carefully controlled ratios. The reactor length typically ranges from 10 to 15 meters, where a significant portion of the reaction between sulfuric acid and ammonia takes place to form ammonium sulfate.

The reaction is highly exothermic, generating sufficient heat to sustain the process without extensive external energy input.

The slurry produced in the pipe reactor is then transferred to the Reaction Granulator. At this stage, controlled quantities of water and additional ammonia are introduced to complete the chemical reaction and stabilize the physical properties of the product. Precise control of temperature, pressure, and reactant ratios is essential for achieving the desired granule size, hardness, and durability.

Granule Cooling and Classification

After granulation, the product is discharged into a Rotary Cooler, where its temperature is gradually reduced and the physical structure of the granules is stabilized. Controlled airflow within the cooling system prevents granules from sticking together or breaking during handling.

Following cooling, the material is conveyed by bucket elevators or belt conveyors to the screening section.

During screening, particles are classified according to size. Oversized granules are directed to a hammer mill or grinding unit for size reduction and recycling. Product-sized granules, typically ranging from 3 to 6 mm, are sent to the packaging section as finished product. Fine particles are recycled back to the granulator to maintain a stable reaction bed and ensure continuous process efficiency.

Emission Control and Material Recovery

One of the major advantages of the Pipe Reactor–Granulator technology is the incorporation of Venturi Scrubber systems. These units collect and treat process exhaust gases and airborne particulate matter generated throughout production.

Dust emitted from equipment such as the rotary cooler is captured through industrial extraction systems and returned to the production cycle. This approach not only minimizes environmental emissions but also significantly reduces material losses, making the process highly sustainable and environmentally friendly.

Crystalline Ammonium Sulfate Production Using the Oslo Crystallizer

In addition to granular production, crystalline ammonium sulfate can be manufactured by incorporating a solution preparation unit and an Oslo Crystallizer into the production line.

The Oslo Crystallizer operates on the principle of controlled, low-turbulence crystallization, providing optimal conditions for the formation of uniform, high-purity crystals.

In this process, a saturated ammonium sulfate solution continuously circulates within the crystallizer through a specially designed internal flow system. By carefully controlling temperature, concentration, and residence time, ideal crystallization conditions are achieved.

The result is the production of transparent, uniform crystals with excellent water solubility, making them suitable for both agricultural and industrial applications.

Advantages of Pipe Reactor–Granulator and Oslo Crystallizer Technologies

• High raw material utilization efficiency
• Consistent product quality with adjustable granule or crystal size
• Extremely low atmospheric emissions through advanced gas and dust collection systems
• Efficient recovery and recycling of suspended solids
• Capability to produce both granular and crystalline ammonium sulfate within a single production facility
• Lower energy consumption compared to conventional production methods
• Environmentally sustainable operation with minimal waste generation

The combination of Pipe Reactor–Granulator and Oslo Crystallizer technologies provides a scientifically proven, cost-effective, and environmentally responsible solution for producing high-quality ammonium sulfate fertilizer.

Manufacturers utilizing these advanced technologies can significantly improve production efficiency while delivering products that meet international quality standards, making them suitable for both domestic markets and export applications.

For more information please contact us.

Manufacturing, Installation, and Commissioning of Livestock, Poultry, and Aqua Feed Production Lines

Atiye Sazan Negin Faraz knowledge-based Company: A Pioneer in Innovative Industrial Solutions, Leveraging Quality and Modern Technology in the Manufacturing, Installation, and Commissioning of Livestock, Poultry, and Aquaculture Feed Production Lines

In today’s competitive landscape, selecting a capable and committed business partner plays a crucial role in the success of enterprises. Atiye Sazan Negin Faraz knowledge-based Company, with its distinguished history in the machinery and feed production industries for livestock, poultry, and aquaculture, has consistently been recognized as a leader in providing innovative and high-quality solutions. We believe that innovation, quality, and customer-centricity are the cornerstones of achieving sustainable growth and maximum customer satisfaction.

One of this Company’s specialized and key areas of activity is providing comprehensive services in the design, manufacturing, installation, and implementation of feed production lines for livestock, poultry, and aquaculture. With a deep understanding of the importance of this industry in the nation’s food supply chain and the need for producing high-quality, cost-effective products, we offer solutions that significantly enhance the productivity of your manufacturing facilities.

Relying on its technical knowledge and specialized workforce, Atiye Sazan Negin Faraz knowledge-based Company possesses the capability to design, manufacture, install, and commission equipment and machinery for livestock, poultry, and aqua feed production lines using the extruder method, tailored to specific customer capacities (even non-standard capacities – higher and lower than usual) for setting up various factories with specific production goals. Furthermore, to enhance the extruder line for producing feed for shrimp and sturgeon, the company has successfully designed, manufactured, installed, and implemented the ECS (Expander Control System) for controlling feed buoyancy.

The aquaculture feed production lines manufactured by our company are capable of simultaneously producing specialized aquaculture feeds under various conditions. This line can simultaneously produce fully floating feed, slow-sinking feed, and fully sinking feed. This means it can produce feed for trout, sturgeon, and shrimp concurrently. This line is capable of producing any type of aquaculture feed with different buoyancy characteristics (100% floating, slow-sinking, and fully sinking) at various capacities. The production capacity for starter and very fine feeds in this production line has increased by 300%, for which a new system has been designed.

The extruder-based aquaculture feed production line equipment comprises over 50 different systems, which are fully automatically controlled from the control room after their layout and integration.

Flowchart of the Aquaculture Feed Production Line

Key Stages in the Implementation of Feed Production Lines for Livestock, Poultry, and Aquaculture:

1. Design and Engineering:

*   Needs Analysis: Precise evaluation of the required production capacity, types of feed (livestock, poultry, aquaculture), raw material specifications, and final product.

*   Technical Design: Preparation of equipment layout plans, Process Flow Diagrams (PFD), Piping and Instrumentation Diagrams (P&ID), and computational design of machinery.

*   Technology Selection: Review and selection of modern technologies and appropriate equipment based on industrial standards and expected performance.

2. Manufacturing and Equipment Procurement:

*   Manufacturing Process: Production of components and assembly of machinery according to approved technical drawings. This stage includes the manufacturing of equipment such as:

    *   Raw material receiving and conveying systems (e.g., elevators, chain conveyors, screw conveyors, Z-type elevators, modular belt conveyors, etc.).

*   Primary processing equipment (e.g., hammer mills).

    *   Mixing systems (e.g., mixers).

    *   Pelleting or forming equipment (pellet press, extruder).

    *   Drying and cooling systems (dryer and cooler).

    *   Packaging and weighing systems.

*   Material Selection: Utilization of high-quality and durable raw materials (such as various carbon steels, stainless steels) in compliance with sanitary and industrial standards.

*   Quality Control: Implementation of technical inspections and performance tests throughout the manufacturing process.

3. Installation and Commissioning:

*   Mechanical Installation: Placement of equipment at the designated site according to the layout plan and connection of components.

*   Electrical and Control Installation: Wiring, connection of electrical panels, programming of control systems (PLC), and testing of automation functionality.

*   Trial Run: Execution of performance tests with raw materials and precise adjustment of operational parameters to achieve the designed capacity and quality.

4. Training and Support:

*   Personnel Training: Provision of necessary training to operators and technical staff on equipment operation, daily maintenance, and safety principles.

*   Technical Support: Provision of technical documentation, maintenance guidelines, and support services throughout the operational period.

For more information please contact us:

+989120275171