MANUFACTURING · FOOD & BEVERAGE · FROZEN & PREPARED FOODS

AI Automation for Frozen & Prepared Foods.

Harmony digitizes paper cook logs and freezer checks, streams the lines live, schedules multi-component builds with AI, and keeps every recipe's genealogy recall-ready. One AI-native operating system over everything: your floor, your machines, and the software you already run. No rip-and-replace.

Start with a pilot ROI Calculators & Tools

THE PROCESS

First a digital transformation. Then an AI transformation.

FIG. 01 · THE TWO ARCS

ARC 1 · DIGITAL

ARC 2 · AI

Data engineering is the work.AI is what it unlocks.

THE PHASED ROLLOUT

Three phases of a digital and AI transformation.

PHASE 01

PHASE 1

Lay the Data Foundation · Digitization

Every pen-and-paper record digitized at the station, every software system connected, and all of the data unified into one live layer. The digital transformation starts here.

PHASE 02

PHASE 2

Production & Operations Scale

Factory operations turn proactive: live sensors and machine data, the AI scheduling board, predictive maintenance before failure.

PHASE 03

PHASE 3

AI-Native Operations

Agents across the floor and the back office act on the live layer: quality signals, reports, copilots. Humans approve.

AI USE CASES

Twelve ways the AI layer earns its keep.

Index · 11 use cases

U1

Paperwork Digitization

Use case 01 · PEN, PAPER & EXCEL

Problem. Recipe batch sheets at the kettle, cook temp logs, freezer check rounds, and assembly checklists on clipboards, keyed into Excel a day later.

Harmony AI Solution. Captured once at the kettle and the line on tablets. AI document processing reads the handwritten backlog into the same layer.

U2

Live Machine Data

Use case 02 · LIVE MACHINE DATA

Problem. Cook temps live on the kettle HMI, freezer temps in the historian, seal parameters on the sealer's panel. Nobody sees them next to each other, or next to the rejects from the same hour.

Harmony AI Solution. Direct PLC and sensor connections, Allen-Bradley/Rockwell, Siemens, Omron, Mitsubishi, any brand, via OPC UA or whatever the machine speaks, stream cook temps, freezer temps, and seal parameters in real time.

U3

In-Line Quality Intelligence

Use case 03 · IN-LINE QUALITY

Problem. Component weights, leakers, and X-ray rejects are tallied after the freezer. Hours of trays carry the same fault before anyone connects it to a machine setting.

Harmony AI Solution. Weights, seal integrity, and X-ray rejects stream live. ML finds the pattern within minutes and signals the depositor or sealer upstream, the same shift the drift starts.

U4

AI Search Across All Data

Use case 04 · AI SEARCH

Problem. "Which lots fed that meal build?" "What did the freezer record overnight?" means binders, three systems, and a walk to the historian terminal.

Harmony AI Solution. Answered in seconds with the source shown, across the ERP, cook logs, machine data, and inboxes. Idle floor TVs become live AI line boards.

U5

AI Production Scheduling

Use case 05 · AI SCHEDULING

Problem. Multi-component builds sequenced around allergen changeovers, kettle capacity, and whether the sauce will be ready, juggled by hand every morning.

Harmony AI Solution. AI production scheduling sequences builds around allergens and component readiness. The plan proposes.

U6

RFID + Serial Genealogy

Use case 06 · LOT GENEALOGY

Problem. Sauce, protein, starch, and film lots live in separate records. A recall question means binders, phone calls, and days of reconstruction.

Harmony AI Solution. Every meal's sauce, protein, starch, and film lot tied together automatically as the build runs. A recall question is answered in seconds, in either direction.

U7

Inventory + Shortage Intelligence

Use case 07 · COMPONENT READINESS

Problem. Assembly starts, then someone discovers the sauce batch is short or the protein is still thawing. The line waits while the plant scrambles.

Harmony AI Solution. Readiness checked against live inventory and the cook schedule before a build releases. Shortages flagged a shift ahead, not at the line.

U8

Yield Optimization

Use case 08 · YIELD + GIVEAWAY

Problem. Giveaway shows up in the monthly numbers. A heavy cavity on the depositor runs all week before anyone catches it.

Harmony AI Solution. Component weights per cavity stream live from the checkweighers. Drift is flagged the hour it starts, and the depositor is adjusted the same shift.

U9

AI Workflow Automation

Use case 09 · COLD CHAIN

Problem. Freezer checks happen on rounds. An overnight excursion is found in the morning, and the disposition debate starts after the fact.

Harmony AI Solution. Spiral freezers and cold storage streamed live. ML flags drift before it becomes an excursion, and an agent raises the alarm before product is at risk.

U10

Inventory

Use case 10 · INVENTORY

Problem. The system shows components that were consumed yesterday, film stockouts get discovered at the sealer, and cycle counts eat weekends.

Harmony AI Solution. An AI-maintained true-stock layer for components, film, and trays. Count drift flagged before it stops a build.

U11

Back-Office AI Automations

Use case 11 · FULL-SCOPE AI AGENTS · FINANCE, SALES, PROCUREMENT, LOGISTICS

Problem. CCP cook and chill logs are written by hand at the kettle and gathered from binders before every audit.

Harmony AI Solution. Full-scope AI agents run the workflows across financial, sales, procurement, and logistics: deductions and AR worked automatically, POs parsed from the inbox, and reports written before the morning meeting.

Scope. Financials, sales, procurement, and logistics automations, in the same platform.

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YOUR LIKELY STACK

The systems and machines we meet on your floor.

SYSTEMS

SAPInfor CloudSuite F&BApteanIgnitionSafetyChainAVEVA historiansCustom appsLocal servers

MACHINES

Groen kettlesLee kettlesDepositorsGEA spiral freezersFPS spiral freezersMultivac tray sealersProseal tray sealersEagle X-rayMettler-Toledo checkweighers

You might run any of these. Or none of them. Harmony is software and hardware agnostic, and we connect live machine data from any PLC brand and any software or custom app.

AI AGENTS

Agents that watch, flag, and act. Humans decide.

Component Readiness Agent

Freezer Sentinel

Seal Integrity Watch

Cavity Weight Agent

Meal Genealogy Agent

Allergen Changeover Guard

AR + Collections Copilot

Deduction Resolution Agent

Morning Report Writer

Custom Agents, built for your floor and back office

THE PATTERN WE SEE

The problems we see on every frozen & prepared foods floor, and why they happen.

The ERP, quality, and freezer records never connect

The ERP holds the order, cook logs live on paper, the historian holds the freezer, and the quality system holds the checks.

Cook temps and counts are written by hand

Recipe batch sheets at the kettle, cook temp logs, freezer check rounds, and assembly checklists are filled in on clipboards.

A meal carries a dozen lots recorded in separate places

The sauce lot is on a batch sheet, the protein lot in the ERP, the starch lot in a receiving log, the film lot on a packaging record.

Overfill and seal failures are counted after the freezer

Checkweigher rejects, leakers, and X-ray kickouts are tallied at the end of the line.

The back office runs on manual work

POs are typed in from emails, invoices keyed into the ERP, deductions and AR worked from spreadsheets, and reports built by hand before the morning meeting.

THE PILOT

$15–20K. 4–6 weeks. One painful problem.

We pick one specific pain point, send engineers to live in your factory for 4–6 weeks, and solve it. One-time payment, working software by week 3, and no obligation to go further. If you do, you choose the modules that you like.

FIRST CALLSECOND CALLCHOOSE PILOTDATA ACCESS FROM ITON-SITEBUILDTESTROIREVIEW

Start with a pilot →Book a Demo →

QUESTIONS, ANSWERED

Do you replace our ERP or our plant systems?

Additive by default. The AI layer sits on top of what you already run, SAP, Infor CloudSuite F&B, Aptean, Ignition, SafetyChain, AVEVA historians, or anything else, and when a system deserves to be replaced, we replace it. Sometimes we're the layer on top of your MES. Sometimes we are the MES. Software and hardware agnostic.

Can you get live data off our kettles, spiral freezers, and tray sealers?

Yes. Direct PLC and sensor connections, Allen-Bradley/Rockwell, Siemens, Omron, Mitsubishi, or any other brand, via OPC UA or whatever the machine speaks, streamed into the AI layer in real time: cook temps, freezer temps, seal parameters, checkweigher and X-ray rejects.

Will the records stand up in a HACCP or customer audit?

That is the point. Cook and chill logs are generated from live kettle and freezer data, complete and timestamped, with the source shown for every value. Baseline first, then measure. Estimates are labeled as estimates.

We run allergens across shared lines. Can the schedule handle it?

Yes. AI production scheduling models your own allergen sequencing rules and component readiness alongside the order book. The plan proposes, the planner approves. Nothing releases that the planner has not seen.

How does the AI get our data?

Read-only connections, scheduled exports, or on-prem. Security is reviewed together in scoping. Read-only pilots. Every agent proposes. A person approves.

What does it cost after the pilot?

A per-plant annual platform: unlimited seats, no user fees, hardware at cost. The pilot itself is $15-20K over 4-6 weeks against one painful problem, with working software by week 3.

Do you work remotely?

No. We always start a pilot in person and on-site, with forward-deployed engineers on your floor. Very rarely do we do anything remotely.

Harmony AI puts the kettle, the freezer, and every component lot on one live layer, so a recall question is answered in seconds, not days.

Start a scoping conversation →

ADJACENT FLOORS WE RUN

Bakery & Snacks →Meat & Poultry →Dairy →