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Rockwell Automation and Actemium have deployed an AI-powered refrigeration optimisation application designed to reduce energy use and improve operational efficiency in frozen food manufacturing.
AI-Powered Refrigeration Optimisation Delivers 17% Energy Efficiency Gain
The autonomous application, known as Real-Time Coefficient of Performance (RtCOP), was developed by Actemium using Rockwell Automation’s PlantPAx distributed control system (DCS). The solution has been implemented at a large producer of frozen french fry products, where it has helped increase energy efficiency by 17%, delivering an estimated $130,000 in annual savings per site.
The system also reduces strain on refrigeration assets, helping improve long-term equipment reliability.
Autonomous Refrigeration Control Targets One of Food Manufacturing’s Largest Energy Loads
Industrial refrigeration can account for up to 70% of a plant’s electricity consumption, making it one of the biggest opportunities for energy optimisation in food and beverage manufacturing.
RtCOP operates as an always-on virtual operator, continuously analysing system capacities, efficiencies and environmental conditions in real time. The application automatically determines and implements energy-efficient operating combinations across compressors, condensers and evaporators.
The solution runs on Rockwell Automation’s PlantPAx modern DCS, providing the real-time data access, processing speed and system transparency required for continuous autonomous optimisation.
Food Producers Face Growing Pressure to Improve Efficiency and Sustainability
“Autonomous optimisation can help food producers conserve energy, reduce costs and ease demands on their workforce,” said Jim Gillis, general manager, Actemium Atlantic Canada.
“Energy-based equipment ranking that is performed continuously and consistently is something human operators simply can’t do in real time. This solution has the potential to transform refrigeration across food manufacturing.”
Kris Dornan, Commercial Marketing Manager at Rockwell Automation said food manufacturers are increasingly seeking technologies that improve operational efficiency while addressing workforce challenges.
Kris Dornan, Commercial Marketing Manager at Rockwell Automation
“Solutions like RtCOP are increasingly needed as food producers face skills shortages, particularly in specialised areas like refrigeration, and pressure to operate more efficiently and sustainably,” said Dornan.
“Technologies like the PlantPAx modern DCS make AI-driven autonomous applications possible, and experienced partners like Actemium make them happen.”
KPI Dashboards Support Multi-Site Benchmarking and Fleet-Wide Deployment
Actemium is now helping the food producer scale the RtCOP solution across its refrigeration plant network.
The deployment includes KPI dashboards designed to provide site-to-site visibility into performance and benchmarking of refrigeration system efficiency across operations.
This article was produced by the editorial team at Food & Beverage Outlook and published as part of the Outlook Publishing global network of B2B industry magazines.
Outlook Publishing delivers industry insights, company stories, and sector coverage across food production, manufacturing, supply chains, construction, healthcare, mining, and sustainability.
Food & Beverage Outlook provides ongoing coverage of organisations and developments shaping the global food and beverage sector.
