Rockwell Automation, the world's largest company dedicated to industrial automation and digital transformation, is helping make one of the most energy-intensive systems in frozen food manufacturing more efficient. Its PlantPAx modern distributed control system (DCS) powers a new autonomous AI-application developed by PartnerNetwork member Actemium, which continuously selects energy‑efficient operating configurations for industrial refrigeration equipment.

Actemium created the solution, known as Real-Time Coefficient of Performance (RtCOP), for a large producer of frozen French fry products. To date, RtCOP helps the food producer increase energy efficiency by 17 per cent, delivering an estimated $130,000 annual savings per site. The solution also reduces strain on refrigeration assets, helping improve long‑term equipment reliability.

RtCOP functions like an always-on virtual operator, continuously analysing system capacities, efficiencies and environmental conditions in real time to determine and implement energy-efficient combinations of compressors, condensers and evaporators.

"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."

The solution runs on Rockwell Automation's PlantPAx DCS, which provides real-time data access, processing speed and system transparency to enable continuous, autonomous optimisation.

Industrial refrigeration accounts for up to 70 per cent of a plant's electricity consumption, making it one of the largest opportunities for energy optimisation in food manufacturing. Historically, these systems are operated to meet cooling demand rather than maximise energy efficiency, in part because operators lack the time and tools to continuously evaluate performance shifts.

"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 Kris Dornan, Commercial Marketing Manager, Rockwell Automation. "Technologies like the PlantPAx modern DCS make AI-driven autonomous applications possible, and experienced partners like Actemium make them happen."