Food Production · Protein & Meat Processing

Chilling Cycle Efficiency

Cut ammonia compressor energy by over 20% while extending MTBF through predictive bearing monitoring.

−22%

Energy per Tonne

Compressor staging optimization cut kWh/tonne from 45 average to 35 over a 60-day period

−39%

Defrost Cycles

Predictive defrost scheduling cut cycles from 6.2 to 3.8/day, recovering 4.1 hours of peak chilling capacity per week

−80%

Unplanned Stops

Predictive Maintenance detected bearing vibration anomaly 3 hours before failure on 2 of 3 events in pilot period

How Allie Works Here

From signal to action in real time.

Energy OptimizationProcess ControlPredictive Maintenance

The Energy Optimization agent monitors compressor suction/discharge ratios across the ammonia loop in real time and adjusts compressor staging via Johnson Controls Metasys API to match actual thermal load, eliminating the fixed 4-compressor-always-on baseline. The Predictive Maintenance agent analyzes motor amperage trends and vibration data from accelerometers on the two primary compressors, flagging subtle bearing degradation signatures 2–4 hours before threshold breach. The Process Control agent manages defrost scheduling dynamically based on evaporator coil frost-load estimation, replacing the fixed time-based schedule.

Machines & Connectivity

OT-connected, protocol-native.

Frigoscandia GYRoCOMPACT Spiral Freezer

JBT Corporation

Modbus TCP

Spiral blast-chilling to 35°F internal product temperature; ammonia refrigeration system

Johnson Controls Metasys BAS

Johnson Controls

OPC-UA

Building automation system controlling ammonia compressor staging and evaporator fan speeds

Emerson Rosemount 3051 Pressure Transmitter

Emerson

Modbus TCP

Suction and discharge pressure monitoring on the ammonia compressor loop

Process Variables

The signals Allie monitors and moves.

Signal Name	Historian Tag	Unit	Baseline	Optimized	Target
Suction Pressure (Compressor Inlet)	`CHILL01.COMP.SUCT`	psig	14–22	17–20	Tighter
Product Core Temp at Spiral Exit	`CHILL01.PROD.CORE`	°F	32–41	35–38	Tighter
Compressor kWh per Tonne Chilled	`CHILL01.KWH.TON`	kWh/t	38–52	31–38	Lower
Defrost Cycle Frequency	`CHILL01.DEF.FREQ`	cycles/day	6.2	3.8	Lower

Suction Pressure (Compressor Inlet)Tighter

CHILL01.COMP.SUCT

Baseline: 14–22 psig→ 17–20 psig

Product Core Temp at Spiral ExitTighter

CHILL01.PROD.CORE

Baseline: 32–41 °F→ 35–38 °F

Compressor kWh per Tonne ChilledLower

CHILL01.KWH.TON

Baseline: 38–52 kWh/t→ 31–38 kWh/t

Defrost Cycle FrequencyLower

CHILL01.DEF.FREQ

Baseline: 6.2 cycles/day→ 3.8 cycles/day

In the Field

"a large-scale poultry processing facility operating three spiral chillers with a combined capacity of 240 tonnes per day"

Deployed at a large-scale poultry processing facility operating three spiral chillers with a combined capacity of 240 tonnes per day. The results above reflect production data from the 60–90 day period following full deployment.

−22%energy per tonne

−39%defrost cycles

−80%unplanned stops

Next Step

See what your lines are actually capable of.

A 30-minute operational assessment. We review your OT/IT setup, identify the highest-ROI deployment, and deliver a scoped pilot proposal.

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