Intelligent Cold-Storage Warehouse
Tutto Porkys · Automated freezing & storage
Design, development and integration of control software for a continuous-freezing, pallet-handling and high-density cold-storage system. Integration with Twins, the proprietary operating software for the stacker crane and freezing tunnel, plus custom operational software to coordinate system operations.
Watch the operations video ↓
System overview
- 544 nominal pallet positions
- 2 storage sides · 17 aisles per side · 4 levels
- Configurable aisle depth: 3 or 4 pallet positions
- Freezing tunnel: 15 levels · 9 trays per level
Engineering challenge
Coordinate freezing, pallet preparation, dimensional checks and automated storage, while recovering interrupted sequences through real-time communication between the mobile module and the PC-based control software over an industrial radio link.
Engineering contribution
PLC software design, development and integration with Twins, the operator-facing digital platform, enabling command and status exchange with a Siemens S7-1516-3 PN/DP PLC via OPC. Technical scope: PLC sequence and interlock development; drive programming; installation and configuration of industrial networks and radio links; and full-system commissioning.
Operating scope
Pallet storage, retrieval and location-to-location exchange; stacker-crane referencing and manual and automatic positioning; tunnel cycle coordination; dimensional-check rejection and operator acknowledgement; equipment status, alarms and interrupted-sequence recovery.
Mobile equipment communications
Integration and commissioning of industrial networks and radio links connecting fixed and mobile control systems. Interface and link configuration, Layer 2 monitoring, authorized-device access control, and industrial communication protocols and cybersecurity measures to support reliable real-time data exchange.
- PC TwinsOperator control
- OPCCommand and status exchange
- Siemens S7-1516-3 PN/DPControl PLC
- Industrial Wi-Fi radio linkLayer-2 monitoring · MAC-based access control
- Mobile modulePLC · drives
Warehouse operations video
Edited on-site footage of warehouse equipment
Project gallery & integrated technologies
The infographic combines the warehouse operating flow and network architecture. The gallery also shows process drawings and project-approved equipment concepts; the cover follows the approved visual direction.
General arrangement of the integrated facility: freezing tunnel, pallet preparation and dimensional-check areas, conveyors, and high-density automated cold storage. The layout shows how the process zones and material-handling systems connect across the warehouse.
The infographic connects the operating flow—from registered product intake and inventory updates to recipe-driven dispatch—with the control architecture. Twins exchanges orders and status with the Siemens S7-1516-3 PN/DP PLC via OPC; industrial Ethernet and a Ubiquiti Loco M5 radio bridge link fixed and mobile networks, including SCALANCE switches, SINAMICS drives and the stacker-crane module.
PC-based management software records incoming products and manages product release according to demand, coordinating conveyor flow with the freezing tunnel and downstream handling. Intelligent control keeps the integrated process sequenced and its operating status coordinated.
At the warehouse outbound, the automated palletizing and wrapping system prepares product loads for dispatch. Its operation follows production orders managed in the ERP, coordinating pallet handling and release from storage.
Virtual commissioning video showing automated warehouse equipment and material-handling sequences in a simulated environment.
Technology & scope
Advanced computer networking · Industrial networks · Industrial radio links · Visual Basic · Siemens TIA Portal · SINAMICS drives · PLC software · Twins · OPC · Siemens S7-1516-3 PN/DP · System commissioning