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.
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) |
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
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
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