Rockwell Automation and industrial solutions provider Actemium have introduced an AI-enabled refrigeration optimization system designed to improve energy efficiency in frozen food manufacturing facilities. The technology has already helped a major frozen french fry producer reduce refrigeration energy consumption by 17 percent, generating estimated annual savings of approximately USD 130,000 per production site.
The solution, known as Real-Time Coefficient of Performance (RtCOP), was developed by Actemium using Rockwell Automation’s PlantPAx® distributed control system (DCS). The system autonomously monitors and adjusts refrigeration equipment operations in real time to identify and implement the most energy-efficient operating configurations.
Industrial refrigeration systems are among the largest energy-consuming assets in food manufacturing plants, often accounting for up to 70 percent of total electricity usage. Traditionally, refrigeration systems are operated primarily to meet cooling demand, with limited ability for operators to continuously evaluate performance changes and optimize energy efficiency under varying environmental and operational conditions.
The RtCOP platform functions as a continuously operating virtual control system that analyzes environmental factors, equipment efficiencies, and system capacities to determine the most efficient combination of compressors, condensers, and evaporators required for plant operations. Actemium stated that the technology enables autonomous optimization that would be difficult to achieve through manual monitoring alone, particularly in large-scale industrial refrigeration environments where performance conditions constantly change.
Jim Gillis, General Manager at Actemium Atlantic Canada, said autonomous optimization technologies can help food manufacturers reduce operational costs, improve sustainability performance, and ease workforce pressures. According to Mr Gillis, continuously ranking refrigeration equipment based on energy efficiency in real time is beyond the practical capabilities of human operators. He stated that the solution has the potential to significantly transform refrigeration management practices across food processing industries.
The RtCOP system runs on Rockwell Automation’s PlantPAx distributed control system, which provides the data processing capabilities, operational transparency, and real-time analytics necessary to support autonomous optimization. Rockwell Automation stated that modern distributed control systems are becoming increasingly important as manufacturers seek to integrate AI-based applications into production operations to improve efficiency, reliability, and sustainability outcomes.
Kris Dornan, Commercial Marketing Manager at Rockwell Automation, said food manufacturers are currently facing growing challenges related to workforce shortages, rising energy costs, and pressure to improve environmental performance.
Mr Dornan stated that AI-enabled applications such as RtCOP demonstrate how advanced control systems can support autonomous industrial operations while helping manufacturers improve productivity and reduce energy consumption. He added that collaborations with technology partners such as Actemium are helping accelerate practical AI adoption across industrial sectors.
The frozen food producer using the technology is currently working with Actemium to scale the optimization system across multiple refrigeration plants within its operations. The deployment also includes KPI dashboards that provide site-to-site visibility into refrigeration performance and allow operators to benchmark efficiency levels across facilities.
Industry experts note that energy optimization is becoming increasingly important for food manufacturers due to rising electricity costs, stricter sustainability targets, and increasing focus on operational efficiency. AI-enabled control systems are emerging as a key technology area for manufacturers seeking to reduce energy intensity while maintaining production reliability.
Rockwell Automation, headquartered in Milwaukee, Wisconsin, operates as a global provider of industrial automation and digital transformation solutions. The company employs approximately 26,000 people across more than 100 countries and focuses on technologies supporting connected manufacturing environments and industrial productivity.
Actemium operates through a global network spanning 40 countries and provides engineering and industrial services across multiple sectors. The company combines local operational expertise with global industrial capabilities to deliver technology-driven manufacturing and process optimization solutions.
