Ready-to-Eat Meals Automated by AutomationDirect

Quick, tasty, and the ultimate convenience: ready-to-eat meals (or RTEs) are a staple of modern life. But have you ever thought about what it takes to guarantee safety and quality in every package? The secret ingredient isn’t always what’s on the label. It’s the advanced automation working behind the scenes. And when a leading RTE kitchen was expanding, they needed a state-of-the-art system to handle everything. That’s where Caldwell Electrical Contractors, a trusted systems integrator, along with their SI Direct partners, came in. Their mission? Cook up a fully automated, turnkey solution. The first task was getting the food where it needed to go. For that, Caldwell integrated specialty conveyors from multiple companies into one seamless system. They even built self-contained enclosures for 40 mobile conveyors to ensure they could be moved anywhere needed. To measure throughput, the system uses continuous in-motion scaling while raw ingredients move from the freezers into the processing line. Now let’s get cooking. When the multiple barbecue ovens fire up, a sophisticated exhaust system where over 67 VFDs and 12 PLCs work together to keep the air pressure just right in every single room. Once completed, every area gets an intense washdown, and even the dirty work is automated. Wastewater flows into equalization, or EQ basins, where blowers keep it mixed. A PLC manages pumps and valves to transfer the liquid and adjust the pH with acid or caustic, all while logging data and generating alarms for the maintenance team. Throughout the facility, Caldwell has installed over 10 Productivity2000 PLC systems and about six CLICK PLC systems. On top of that, numerous C-more HMI panels and remote HMIs allow for operator interaction. Caldwell also took advantage of the StrideLinx remote VPN system, developing their own Wise ViewPoint mobile app that they use to monitor everything—from conveyor status to oil inventory and wastewater treatment—right on their phone. When it comes to delicious ready-made food, automation ensures every meal is prepared safely, reliably, and consistently. The results of this successful collaboration prove that automation is the secret sauce for modern, successful food production. To read more about this story and other customer applications, visit our library site. To learn more about these products and many others, visit us today at automationdirect.com.