Costa Logistics operates a critical cold storage facility responsible for delivering fruit and vegetables to all Coles stores across Western Australia. To maintain the quality and freshness of perishable goods, the facility relies on efficient and reliable refrigeration systems. The existing control system, based on an Allen Bradley PLC, had become outdated, leading to inefficiencies and potential risks to product integrity. 

MECS Electrical & Controls was tasked with modernizing the control infrastructure to enhance system reliability, improve energy efficiency, and provide better monitoring and control capabilities. 

Execution Strategy: 

Assessment and Planning: 
Conducted a comprehensive evaluation of the existing refrigeration control system to identify deficiencies and areas for improvement. Developed a detailed project plan outlining the steps for decommissioning the old system and implementing the new Danfoss control solution. 

System Decommissioning: 

Safely removed the outdated Allen Bradley PLC, ensuring minimal disruption to ongoing operations. This process involved careful disconnection and removal of legacy hardware while maintaining the integrity of the refrigeration systems. 

Danfoss System Installation: 

Hardware Setup: Installed the new Danfoss control hardware, including controllers and associated components, to manage the two refrigeration racks and cool rooms. 

Software Configuration: Configured the Danfoss software to optimize refrigeration processes, set parameters for temperature control, and establish monitoring protocols. 

Integration and Testing: 

System Integration: Integrated the new control system with existing refrigeration equipment, ensuring seamless communication between components. 

Comprehensive Testing: Performed rigorous testing to validate system functionality, including stress tests under various load conditions to ensure reliability and performance. 

Training and Handover: 

Staff Training: Provided training sessions for Costa Logistics personnel to familiarize them with the new Danfoss system, covering operation, monitoring, and basic troubleshooting. 

Documentation: Supplied detailed documentation, including system manuals and configuration guides, to support ongoing maintenance and operation. 

Challenges and Solutions: 

• Maintaining Operational Continuity: 
  Ensuring uninterrupted refrigeration during the upgrade was critical to prevent spoilage of stored produce. MECS implemented a phased approach, allowing sections of the system to be upgraded sequentially while others remained operational, thereby maintaining continuous cooling. 

• System Compatibility: 
  Integrating the new Danfoss system with existing refrigeration infrastructure required careful planning to ensure compatibility. Customized interfaces and configurations were developed to facilitate seamless integration. 

• Minimizing Downtime: 
  The project was executed within a tight timeframe to minimize downtime. Efficient project management and scheduling ensured that the upgrade was completed promptly without compromising quality. 

Outcome: 

The refrigeration control system upgrade at Costa Logistics was successfully completed, resulting in enhanced system reliability, improved energy efficiency, and better control over refrigeration processes. The new Danfoss system provides robust monitoring capabilities, allowing for proactive management and maintenance, thereby ensuring the consistent quality of perishable goods distributed to Coles stores throughout Western Australia. 

Client Feedback: 

Costa Logistics expressed satisfaction with the professionalism and expertise demonstrated by the MECS Electrical & Controls team. The seamless transition to the new control system and the minimal disruption to operations were particularly appreciated.