Food Manufacturing | EMS Controls Upgrade

Knead for Speed

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.

The Problem

A Pizza Dough plant on the outskirts of Phoenix, AZ, relied on an outdated RMCC refrigeration monitor control unit to manage its rack system.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.

The Solution

State-of-the-Art Monitoring Platform

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.

Precision Planning, Coordinated Execution

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.

The Impact

Through precise execution and proactive troubleshooting, CoolSys exceeded project expectations, completing the upgrade early and creating lasting operational improvements for the client.

Completed Ahead-of-Schedule

By 2 PM on Saturday—an impressive 10 hours early—the team had completed the cut-off, removed outdated sensors, boards, and equipment, installed the new system, the sensors, the boards, and conducted thorough testing before restarting the rack.

Client Confidence Secured

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.

Proactive Issue Resolution

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.

Expanded Partnership

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.

Project Highlights

To Complete EMS Update

0 hrs

New Sensors & Boards Installed

0 x

Ahead of Schedule

0 hrs

Ready to Discuss Your Next Project?

Ready to optimize your control systems and meet aggressive timelines? Contact CoolSys to see how our experts deliver reliable, future-ready solutions.

Knead for Speed

The Problem

The Solution

State-of-the-Art Monitoring Platform

Precision Planning, Coordinated Execution

The Impact

Completed Ahead-of-Schedule

Client Confidence Secured

Proactive Issue Resolution

Expanded Partnership

Project Highlights

Ready to Discuss Your Next Project?

Related Reading

Reduce Energy Costs Across Multi-Site Facilities

HVAC Lifecycle Cost Analysis

HVAC Repair or Replace

Heat Pumps for Commercial Buildings: When Do They Make Sense?

Sitemap

We're Here to Help

Let’s Move Forward. Together.