1. The Problem

Food processing facilities required advanced freezing tunnel systems capable of handling high-volume production (up to 20,000 kg/h) while maintaining strict quality standards for texture, color, flavor, and nutrients. Traditional freezing systems lacked the automation, flexibility, and monitoring capabilities needed for modern meat processing operations. Facilities needed a solution that could adapt to different products and packaging types while ensuring compliance with food safety regulations and providing complete operational visibility.

2. The Solution

The company developed fully automated refrigeration tunnels integrated with Tatsoft's industrial automation platform, creating a comprehensive freezing/cooling system for medium to large-scale poultry, pork, and beef processing facilities. The solution handles products in cardboard or plastic containers with rapid freezing capabilities (down to -40°C), preserving product quality through precise temperature control and automated handling.

The system architecture leverages Allen-Bradley PLCs for central control, integrated with extensive I/O points and real-time monitoring through CFTV cameras, all managed through Tatsoft's SCADA platform with MQTT connectivity for supervisory-level integration.

Simple Architecture Diagram:


Freezing Tunnel Equipment (7,000-13,000 I/O Points)
         ↓
Allen-Bradley PLC (Ethernet/IP Protocol)
         ↓
Tatsoft SCADA Platform (10,000-16,000 Internal Tags)
         ↓
MQTT Server (Supervisory Level)
         ↓
20 Operator Screens + 10 Hikvision CFTV Cameras
         ↓
Rittal Electrical Panels Integration

Technical Specifications:

  • I/O Points: 7,000-13,000 communication points per tunnel

  • PLC Platform: Allen-Bradley with central control architecture

  • Network Protocol: Ethernet/IP (tunnel level), MQTT (supervisory level)

  • SCADA Configuration: 10,000-16,000 internal tags

  • HMI Screens: 20 operator interfaces

  • Vision System: ~10 Hikvision CFTV cameras per installation

  • Electrical Infrastructure: Rittal electrical panels

  • Processing Capacity: Up to 20,000 kg/h

  • Temperature Range: Down to -40°C rapid freezing

  • Deployed Systems: 50+ tunnels operational in Brazil and internationally

3. Key Enablers

  • High-Density I/O Management: Efficient handling of 7,000-13,000 communication points per tunnel

  • Multi-Protocol Architecture: Ethernet/IP for real-time control, MQTT for supervisory integration

  • Scalable Tag Structure: 10,000-16,000 internal tags supporting complex process logic

  • Integrated Vision System: CFTV cameras providing real-time product monitoring and quality control

  • Flexible Product Handling: Adaptable to various products, packaging types, and freezing requirements

  • Rapid Freezing Technology: Evaporators designed for -40°C operation preserving product quality

  • Comprehensive HMI Design: 20 screens providing complete operational visibility and control

4. The Results

  • Successfully deployed 50+ automated freezing tunnels in Brazil and international markets

  • Achieved processing capacity of up to 20,000 kg/h with consistent quality standards

  • Preserved product quality (texture, color, flavor, nutrients) through rapid freezing technology

  • Enabled flexible operations adaptable to different products and packaging requirements

  • Met stringent food safety and quality regulations through automated control and monitoring

  • Provided complete operational visibility through integrated SCADA and CFTV systems

  • Established this company as a leading provider of industrial freezing solutions for meat processing facilities

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