Rockwell Automation’s AI Cuts Frozen Food Refrigeration Energy Use 17%, Saves $130K per Site
ROK•Rockwell Automation’s PlantPAx DCS powers Actemium’s Real-Time Coefficient of Performance AI application to cut industrial refrigeration energy use in frozen food production by 17%. The system delivers an estimated $130,000 in annual savings per site while reducing equipment strain and improving reliability.
1. AI-Driven Refrigeration Optimization
Rockwell Automation and partner Actemium developed the Real-Time Coefficient of Performance (RtCOP) autonomous AI application to continuously optimize industrial refrigeration systems. RtCOP analyzes capacities, efficiencies and environmental conditions in real time to select the most energy-efficient combinations of compressors, condensers and evaporators.
2. Energy and Cost Benefits
Implementing RtCOP in a large frozen french fry production facility yielded a 17% reduction in refrigeration energy consumption and approximately $130,000 in annual savings per site. The continuous optimization also lessens mechanical strain, enhancing long-term equipment reliability.
3. Integration with PlantPAx DCS
RtCOP is powered by Rockwell Automation’s PlantPAx modern distributed control system, which provides high-speed data access, processing and system transparency. This integration enables the AI to operate as an always-on virtual operator, executing efficiency adjustments without manual intervention.
4. Scalability and Reliability
Actemium is rolling out RtCOP across the food producer’s fleet of refrigeration plants, using KPI dashboards for site-to-site performance benchmarking. The solution addresses workforce skill shortages in specialized refrigeration roles while advancing sustainability goals through energy optimization.
