Engineering at 35°F: How Imperium Built a Cohesive Pizza Packaging Line from Five OEM Systems

In Part 1 of this case study, we introduced the integration challenge at a new 110,000 sq ft food commissary in east Tennessee: five different OEM machines, each with its own controller, needed to operate as a single coordinated pizza packaging line. In Part 2, we get into how Imperium Technology Solutions (Imperium) actually built it — and what it took to deliver in a sub-freezing operating environment.

Building a Cohesive System

At the heart of Imperium's solution was a master control architecture built around a CompactLogix Safety PLC from Rockwell Automation. This system served as the supervisory control layer, enabling communication between independently controlled machines while also managing the custom conveyor system.

Imperium's controller facilitated:

•         Integration of conveyor systems transporting product from metal detection through case packing and recirculation.

•         Coordinated start/stop, fault handling, and emergency stop interlocks across all equipment via a combination of controller-to-controller communication and discrete 24VDC signal exchange for compatibility with varying OEM systems.

•         Control of PowerFlex 525 variable frequency drives (VFDs) for conveyor and gates operations.

•         Centralized visualization via low-temperature HMI stations, providing operators with real-time data from both packaging and upstream processing equipment.

Imperium extended visibility beyond the packaging area, incorporating data from upstream processing systems, including equipment located before the linear flash freezer. This allowed operators to monitor the entire production flow from a single interface.

Engineering for Extreme Conditions

One of the most demanding aspects of the project was the operating environment. Much of the packaging integration occurred downstream of a linear flash freezer, where ambient temperatures hovered around 35°F.

This required specialized design considerations, including:

•         Heated control panels and enclosures to maintain component reliability

•         Low-temperature-rated HMI screens for operator use

•         Strategic placement of control hardware in constrained spaces, often within refrigerated areas

Installation crews faced significant physical challenges working in cold conditions. To maintain productivity and safety, personnel rotations were implemented throughout the installation and commissioning phases.

Conveyor Innovation and Line Performance

The conveyor system, designed and supplied by the prime contractor OEM, was a critical component of the overall solution. It included multiple sections for product transport, recirculation, and full case handling, all tightly integrated with the packaging equipment.

The system was engineered for high-speed operation with minimal accumulation. This required precise synchronization across all machines to avoid bottlenecks or product disruption. Several challenges were addressed during implementation:

•         Traction issues caused by condensation and interaction between frozen products, shrink wrap, and labeling processes

•         Tight layout constraints, requiring conveyor modifications to accommodate sharp turns and efficient product flow

•         Accumulation control, including the integration of pin-stop mechanisms and additional safety disconnects to meet code requirements

Despite these complexities, the system achieved smooth, continuous operation through careful tuning of conveyor speeds, interlocks, and machine coordination.

The Value of Integrated Collaboration

A key factor in the project's success was the close collaboration between the prime contractor OEM, Imperium, and ASBECO. With ASBECO serving as the installation lead and primary project management interface, the team operated with a unified approach to execution. The "three-legged stool" model — combining controls integration with mechanical and electrical installation services — enabled Imperium and ASBECO flexibility in responding to changes, including:

•         Last-minute panel modifications

•         Addition of ancillary equipment during the project lifecycle

•         Real-time adjustments to programming and system logic

By maintaining a single point of contact for the end customer and aligning internal teams, the project minimized delays and streamlined decision making. (For more on how Imperium and ASBECO work together, see our earlier post on close-knit team collaboration.)

Delivering Results

From proposal in mid-2024 to commissioning in April 2025, the project progressed on an aggressive timeline. Despite environmental challenges, system complexity, and evolving scope, the integrated team delivered:

•         A fully coordinated packaging line connecting multiple OEM machines

•         Real-time visibility across processing and packaging operations

•         Reliable performance in the refrigerated environment

•         On-time project completion

•         Cost control aligned with project changes

Enabling Scalable Food Production

As foodservice operations continue to evolve, the ability to integrate diverse equipment into cohesive, high-performing systems is increasingly critical. This project demonstrates how Imperium brings together controls engineering, system design, and cross-platform integration to deliver solutions that scale with customer needs.

By transforming a collection of independent machines into a unified production line, Imperium helped enable efficient, high-quality pizza packaging — supporting a broader vision of fresh food production at scale.

Planning a similar project?

Whether you're standing up a new commissary, modernizing an existing line, or integrating equipment from multiple OEMs, Imperium's controls engineering team can help. Contact us at sales@imperiumtechllc.com or (470) 253-1055.