Project Profile
Ammonia Refrigeration Controls Modernization for Cincinnati Bakery
Client:
Withheld
Location:
Cincinnati, Ohio
Sector:
Food Manufacturing
Project Profile
Project Description
A major Cincinnati bakery partnered with Davies Engineering Group to modernize its ammonia refrigeration controls. The project focused on upgrading the engine room and evaporator control systems to improve efficiency, visibility, and safety. Our Controls Team consolidated three legacy PLCs into a centralized Allen-Bradley platform and deployed Ignition SCADA for real-time monitoring, remote access, and historical data logging. The project was executed in carefully planned phases to avoid any unplanned production interruptions.
Client feedback highlighted the value of the improved visibility and control, remote monitoring capabilities, and energy insights gained through the new system. While the scope centered on controls, Davies also provides full ammonia system design—including mechanical engineering, safety compliance, and process optimization.
Key Successes:
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Simplified controls and HMIs provided significantly improved visibility of ammonia processes
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Ignition SCADA with remote access and data logging enabled better energy monitoring
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Estimated 25–30% reduction in liquid ammonia usage in the freezer due to optimized setpoint control
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System changes reduced unnecessary liquid feed, lowering compressor demand
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Enhanced safety with upgraded ammonia sensors and code-compliant E-stop systems
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Seamless phased execution with no unplanned production downtime
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Client praised the team for “excellent communication and follow-through on all objectives”
Services:
Controls Modernization and SCADA Integration
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Consolidation of three legacy PLCs into a single Allen-Bradley control platform
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Ignition SCADA deployment with historian, alarming, and multi-user access
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Replacement of outdated PanelView HMIs with modern, scalable visualization
Safety and Process Optimization
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Installation of new ammonia detection sensors and code-compliant E-stop systems
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Reprogrammed evaporator control logic for demand-based liquid ammonia flow
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Remote access and data logging for improved operational insight and diagnostics