CHALLENGE:

A client running spiral freezer operations kept running into the same headaches: every system was built differently. That meant higher engineering bills each time a new unit was added, longer training curves for operators, and more time lost troubleshooting issues that shouldn’t have been complicated in the first place.

They needed one consistent, scalable solution that could be rolled out across multiple sites without reinventing the wheel each time.

SOLUTION:

Actemium designed a complete, comprehensive control system built around three core components:

  • CompactLogix PLCs — handle all the process automation, including conveyor sequencing, fan control, and nitrogen system safety interlocks
  • PanelView Plus 7 HMIs — give operators a clean, intuitive touchscreen interface that looks and works the same at every installation
  • PowerFlex VFDs — manage conveyor belt speed and air correction fans for smooth, efficient operation

On top of that, TosiBox secure remote access was integrated so the team can diagnose issues and push updates without needing to be on-site.

The enclosure? A rugged NEMA 4X stainless steel panel built to hold up in cold, wet freezer environments.

HOW IT CAME TOGETHER:

Actemium handled the full scope — electrical design, PLC programming, HMI development, and on-site startup and testing. The client brought deep process knowledge to the table, and the two teams worked closely together to make sure the system fit seamlessly into real production conditions.

RESULTS:

Once the system was live, the benefits were immediate and measurable:

  • Lower costs — future installations require far less engineering time since the design is already proven
  • Easier training — operators learn one interface, and that knowledge carries across every site
  • Better reliability — consistent architecture means fewer surprises and faster troubleshooting
  • Remote support — issues can often be resolved without a site visit, saving time and money

When control systems are standardized, everyone wins — less engineering overhead, safer operations, and a smoother experience for the people running the equipment day to day. This project is a strong example of how investing in a consistent architecture up front pays dividends across every future installation.


Want to learn more? Contact us for details about our services and how we can help your operations run smarter and faster.