Rockwell Automation deploys AI system for refrigeration energy reduction in frozen food plants

What happened: Rockwell Automation and Actemium developed an AI application that reduces industrial refrigeration energy consumption by 17 percent. The solution, called Real-Time Coefficient of Performance, runs on the PlantPAx distributed control system. The system continuously selects energy-efficient operating configurations for refrigeration equipment. Construction is scaling the solution across multiple refrigeration plants.

Why it matters: Industrial refrigeration accounts for up to 70 percent of electricity consumption in food manufacturing facilities. The autonomous application optimizes refrigeration systems by analyzing capacities, efficiencies, and environmental conditions in real time. The system determines optimal combinations of compressors, condensers, and evaporators. Human operators lack time and tools to continuously evaluate performance shifts. The solution also reduces strain on refrigeration assets, improving long-term equipment reliability.

Industry context: Food producers face skills shortages in specialized areas like refrigeration alongside pressure to operate more efficiently and sustainably. Energy costs represent a major operational expense in frozen food production. The deployment demonstrates how AI applications can address both workforce constraints and sustainability targets simultaneously. Dashboards enable site-to-site visibility and benchmarking of system efficiency across multiple locations.

Our take: Classic AI use case – moving from pilot projects to measurable operational impact in industrial settings. Repeatability across multiple sites will determine whether energy optimization becomes a standard capability and not a custom implementation.