Future-proofing frozen food production through automation modernisation

Project summary

Sector: Feed, Food & Beverage
Customer: Major frozen food manufacturer
Location: United Kingdom
Project duration: 18 months
Expertise: Industrial Automation |Control Systems | Systems Integration | Electrical Engineering | Control Panel Design & Manufacture | Installation & Commissioning

Key facts:

• 2 high-capacity production lines modernised concurrently
• 15–25 tonnes per hour of finished-product throughput
• 150+ variable speed drives
• 16+ motor control centre sections
• 40+ remote control nodes
• 6+ specialist equipment suppliers integrated into each production line

The challenge: Improving performance without disrupting production

In high-volume food manufacturing, even short interruptions can affect output, product consistency and operating costs. Keeping production running efficiently therefore depends on reliable equipment, well-coordinated processes and the ability to respond quickly when problems arise.

At this UK frozen food facility, ageing control systems were making that increasingly difficult. Recurring stoppages affected output, while limited fault diagnostics made it harder for maintenance teams to identify and resolve issues. A lack of detailed reporting also restricted visibility of how the lines were performing.

The manufacturer wanted to address these challenges, improve product quality and increase production capability. At the same time, it needed to minimise disruption during the upgrade.

Adding to the complexity, each line incorporated equipment from multiple specialist suppliers. These covered everything from raw material preparation and cooking to freezing, packaging and cold storage. Ensuring the different systems worked together effectively was essential to achieving the required performance.

The solution: Bringing the entire production process together

With extensive experience in snack and frozen food manufacturing, Actemium Automation Peterborough, part of Actemium UK, was appointed to deliver the upgrade across both lines.

The team managed the project from initial engineering and design through to software development, control panel manufacture, systems integration, testing and commissioning.

This end-to-end approach provided the manufacturer with greater coordination across multiple suppliers and interconnected processes, helping identify potential challenges early and streamline delivery.

Designing automation systems around the manufacturer’s processes

Actemium began by reviewing the manufacturer’s operational requirements and how each stage of production needed to work together, from raw material intake through to the finished product.

Using this understanding, the team developed an integrated control strategy to coordinate equipment, manage changing process conditions and support reliable, consistent production.

The design covered everything from equipment sequencing and safety interlocks to recipe management, product changeovers and performance reporting. Early engineering reviews also helped identify potential issues with existing equipment, network connections and installation requirements. Addressing these before work began on site reduced the risk of delays and disruption later in the project.

To deliver the required performance, Actemium developed an automation platform using proven industrial technologies, including:

• Rockwell Automation ControlLogix PLCs to manage and coordinate production processes
• FactoryTalk View HMI systems to give operators clear visibility and control
• EtherNet/IP industrial networking to enable reliable communication between equipment
• 150+ variable speed drives, including PowerFlex 525 and ABB drives, to provide precise motor and conveyor speed control
• Distributed I/O and managed network switches to connect equipment and support efficient fault diagnosis

Making multiple systems work as one

A key part of the project was bringing together equipment from more than six specialist suppliers on each production line.

Actemium integrated the controls across the entire manufacturing process, from raw material reception, washing and preparation through to cooking, freezing, packaging, palletising and transfer to cold storage.

By connecting these different systems, Actemium enabled the equipment to operate as one coordinated production line. Conveyor speeds, operating sequences and safety interlocks were synchronised to maintain stable processing conditions as products moved through each stage.

This level of control was particularly important for product quality. Consistent recipe management and precise process control helped create repeatable manufacturing conditions, reducing the risk of product variation and waste.

The new system also simplified day-to-day operations. Automated start-up and shutdown sequences reduced the need for manual intervention, while improved alarms and fault diagnostics made it easier for maintenance teams to identify and resolve problems.

With better production tracking and reporting, the manufacturer gained a clearer picture of line performance. This provided valuable insight into downtime, efficiency and opportunities for continuous improvement.

Delivering a controlled transition to the new systems

With both production lines being upgraded concurrently, careful planning and testing were essential to minimise disruption.

Actemium designed and manufactured the control panels in-house, bringing together the electrical engineering and automation expertise needed for the project. The panels, software and system interfaces underwent factory acceptance testing before delivery to site. This allowed potential issues to be identified and resolved early, helping reduce delays during installation and commissioning.

Once on site, the team supported installation and carried out electrical checks, network validation, drive commissioning and safety verification.

Commissioning followed a phased approach, starting with dry running before progressing to testing with product. The team then fine-tuned the systems during production ramp-up to optimise performance under normal operating conditions.

To support a smooth handover, Actemium also provided operator training, ensuring the manufacturer’s teams had the knowledge and confidence to operate, monitor and maintain the upgraded lines.

The results: Smarter automation, greater reliability and better operational performance

The completed upgrade gave the manufacturer a more reliable, manageable and scalable automation platform across two high-capacity production lines.

Key customer benefits included:

• Improved product quality and consistency: Precise process control, equipment synchronisation and recipe management supported repeatable manufacturing conditions, helping minimise product variation and the risk of waste.
• Higher productivity: Coordinated equipment operation, automated sequences and faster changeovers supported more efficient production with less manual intervention.
• Greater reliability and faster fault resolution: Modern controls and improved diagnostics helped maintenance teams identify and resolve problems more quickly, reducing the risk of prolonged stoppages.
• Better operational visibility: Real-time monitoring and production reporting provided clearer insight into throughput, downtime and opportunities to improve efficiency.
• Improved maintainability and future readiness: Replacing obsolete controls with a scalable architecture made the systems easier to support and provided flexibility for future upgrades and expansion.

Helping food manufacturers improve performance through industrial automation

With more than four decades of experience, Actemium Automation Peterborough specialises in delivering integrated automation solutions for food and beverage manufacturers, helping improve product quality, productivity and reliability.

From initial engineering and design to software development, control panel design and manufacture, systems integration and commissioning, the team provides end-to-end solutions tailored to each manufacturer’s needs. Ongoing lifecycle support also helps customers maintain performance and protect their investment.

Whether upgrading existing production lines or developing new facilities, Actemium Automation Peterborough combines specialist expertise with trusted delivery to help manufacturers improve operations and prepare for future growth.