Food Manufacturing | EMS Controls Upgrade
Efficient Upgrade for Major Pizza Chain’s Dough Facility
A Pizza Dough plant, running multiple shifts and producing over 10,000 pizza doughs daily for restaurants across multiple states, could not afford to slow down operations to implement a critical RMCC refrigeration monitor control unit upgrade.
A Pizza Dough plant on the outskirts of Phoenix, AZ, relied on an outdated RMCC refrigeration monitor control unit to manage its rack system. The aging unit was inefficient, underperforming, and provided minimal data, making an upgrade essential. The plant, running multiple shifts and producing over 10,000 pizza doughs daily for restaurants across multiple states, could not afford to slow down operations to implement the upgrade.
Replacing the system was a critical project that required precise timing. The upgrade had to be completed within a tight window, starting Friday at 6 PM and finishing by Saturday at midnight, ensuring the system was fully operational by Sunday at 2 AM.
CoolSys selected Copeland CPC E3 controls, replaced all sensors and boards with brand-new units and tripled the quantity of the existing RMCC, to create a robust monitoring platform that exceeds current best practices. This enhanced system delivers precise predictive analytics, quickly identifies the root causes of issues, and offers seamless online and offline access.
To meet the project’s tight deadlines, CoolSys developed a meticulous hour-by-hour project plan. This included offsite programming and testing of the units, cell modem, boards, and sensors. The design and installation teams collaborated using annotated photos and detailed on-site markers, enabling precise coordination of tasks well in advance of entering the facility.
Through precise execution and proactive troubleshooting, CoolSys exceeded project expectations, completing the upgrade early and creating lasting operational improvements for the client.
By 2 PM on Saturday—an impressive 10 hours early—the team had completed the cut-off, removed outdated sensors, boards, and equipment, installed the new system, the sensors, the boards, and conducted thorough testing before restarting the rack.
The client’s Senior Engineer, who flew in to oversee the project, was highly impressed by CoolSys’ preparation, technical expertise, and flawless execution. As a result, he updated internal requirements to use CoolSys teams for all future control system upgrades exclusively.
With the extra time from early project completion, the CoolSys team leveraged their advanced platform to address recurring flood-back issues. They identified the root cause and fixed the issue, ensuring long-term reliability.
Already relying on CoolSys for HVAC and refrigeration services, the restaurant chain expanded its partnership to include assistance with power loss issues and energy monitoring, further solidifying CoolSys as a trusted and invaluable partner.
To Complete EMS Update
New Sensors & Boards Installed
Ahead of Schedule
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