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If you purchased an Avocado this year with a sticker on it proclaiming, “Produce of California” or “Produce of Mexico,” there is a good chance it came from a ripening facility being operated by an Airixa refrigeration control system.

Process Solutions recently deployed a team of engineers to Mexico to commission new Airixa refrigeration control systems that were installed in two separate Avocado processing and storage facilities.

The first avocado facility was stocked with millions of dollars worth of product, which meant the system could not be down for more than 3 hours. To minimize downtime, we developed wiring harnesses that included mating connectors that plugged directly into the existing control system wiring. By using the wiring harnesses, Process Solutions’ engineering team was able to install the entire new system in a single work day.

To operate the facilities refrigeration equipment and fans, Airixa utilizes a Siemens S7-1500 series PLC ,  and ET200SP I/O rack. Additionally, the Airixa system includes energy management software that works to reduce energy consumption with intelligent load management and start-up sequencing capabilities.  Because of Airixa’s modern hardware and software capabilities, we were able to replace 11 controls units with just one PLC, significantly reducing the systems footprint and maintenance requirements, while boosting overall efficiency.

In addition to the PLC components, the new Airixa system included a combination of 67 variable frequency drives, 7 RTU to Modbus converters, and a fiber-optic cable to connect the system between two remote locations at the facility.

Once installation was complete, Airixa began operating 2 separate engine rooms with 7 refrigeration compressors, 6 condensers, 10 suction accumulators, and 2 Freon detectors, along with 15 cooler rooms housing 57 evaporators.

The second Airixa system we installed in Mexico was considerably smaller; however, it still  provided a significant boost to the efficiency of the plant’s operations. After replacing the existing legacy control units, Airixa took over operation of the facility’s engine room, which included a chiller and glycol circuit, along with 3 refrigeration compressors, 5 condensers, and 4 cooler rooms with 14 air units. In order to run all of these machines, the Airixa system was equipped with 30 Siemens G120 series VFDs.

Airixa is a technology platform for the control of industrial refrigeration systems and energy management. With Airixa, companies can reduce peak energy demands and run their facility at optimal efficiency without sacrificing operational performance. To learn more about Airixa, please visit www.processsolutions.com/airixa.

Panel Example 1
Drive Panel Example
Stacklight Panel Example
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Panel Example 6
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Panel Example 3
Panel Example 4
Panel Example 2
GE PLC Panel
VFD Panel Example 2
HMI Enclosure Interior Example
PLC Example Two
PLC Panel 2-door Example
Sloped Enclosure Example
Stainless Steel PLC Panel Example
Three Door VFD control panel with remote I/O and a disconnect switch
Two Door Panel Example
Two-door VFD Control Panel in stainless steel enclosure
Custom Control Panel with Servo Drives Installed
Custom PLC Control Panel Built by Process Solutions
Industrial Control Panel With and IO rack and Stainless Steel Enclosure
Custom Control Panel Builder
Electrical Control Panel in Stainless Steel Enclosure
VFD control panel with yellow terminal wiring
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Vaclav Mydlil
Sr. Director of Advanced Automation
Vaclav leads the dynamic Energy Management and Refrigeration Division at Process Solutions. With an impressive 20 years of experience in power demand management and refrigeration control systems, Vaclav is the driving force behind one of the company’s most innovative systems.

His expertise extends to PLC and cloud-based systems, ensuring seamless integration and optimal performance. Vaclav’s commitment to excellence is underscored by his Master of Science degree, specializing in control systems and electrical engineering, which he earned from the University of Life Sciences in Prague, Czech Republic.

Beyond the office, Vaclav’s passions include kayaking, snow skiing, and woodworking. Most of all, he enjoys moments spent with his wife and three kids.
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Steve Pelton
Vice President of Sales
With over 20 years at Process Solutions, Steve Pelton has held various roles, including Sales Engineer, Sales Director, and his current position as Vice President of Sales.

In addition, Steve oversees Process Solutions’ Energy Management and Refrigeration Division — ensuring the company remains at the forefront of energy-efficient solutions that cater to diverse food production applications. Steve also spearheads the strategic development of the company’s machine monitoring solutions, aligning them with client needs and market trends.

Steve’s background includes mechanical engineering, but his career trajectory has mainly focused on control systems marketing and management. His ability to bridge technical expertise with business acumen has been instrumental in Process Solutions’ growth.

Outside the office, Steve passions include conquering rugged trails on his mountain bike, perfecting his golf swing, and exploring new destinations with his family.
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Matt Barnes
Chief Financial Officer
Matt, with 28 years of financial strategy and accounting experience, plays a pivotal role at Process Solutions. As the Chief Financial Officer (CFO), he spearheads the company’s growth strategy, ensuring financial stability and health.

Beyond traditional financial management, Matt also oversees strategic initiatives aimed at optimizing Process Solutions’ on-hand inventory costs and availability. By fine-tuning inventory management, Matt ensures the company can meet client needs efficiently and maintain a healthy bottom line.

Matt graduated with a degree in accounting from Western Washington University and previously served as a financial executive at a large retail corporation. Outside of work, Matt enjoys traveling, soccer and spending time with his family.
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Kevin Orr
Executive Vice President
Kevin boasts an impressive tenure of over 25 years at Process Solutions. His position in the company has been multifaceted, spanning roles as a project engineer, engineering manager, and Process Solutions’ first Executive Vice President.

Under Kevin’s leadership, the food processing division has flourished, earning its reputation as of the most respected in the industry. Today, Kevin closely collaborates with executives from leading food processors and food processing equipment manufacturers across the country.

Kevin is a devoted husband and father with a passion for international travel.
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Todd Busby
Chief Executive Officer
Todd has dedicated over 30 years to Process Solutions, where he has worn multiple hats—from panel builder to project engineer and sales representative.

As the CEO of Process Solutions, Todd has spearheaded significant transformations. Under his leadership, the company has diversified into new industries, acquired a world-class facility, and more than doubled its size.

Todd, a native of the Puget Sound region, is a devoted husband, father, and avid outdoorsman. When he’s not at work, you’ll find him supporting his three kids in all their pursuits or hunting and fishing in Eastern Washington.
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David Crumpley
President
David has dedicated over 15 years to Process Solutions, where he has served as a Senior Engineer, Vice President, and now Chief Operating Officer. His multifaceted experience spans technical expertise, strategic leadership, and operational efficiency.

As the head of Process Solutions’ Water/Wastewater division, David orchestrated the modernization of the company’s internal systems and boosted operational efficiency across the organization.

In his current role as President, David continues to drive innovative initiatives aimed at expanding the company’s reach and further streamlining internal processes.

Outside of work, David enjoys spending quality time with his family and pursuing his passions as an avid outdoorsman.
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We provide numerous remote and on-site services to our customers, including software upgrades, troubleshooting, hardware replacement, and feature additions. Our staff size provides us flexibility to quickly respond to standard time frames and emergency service.
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Process Solutions provides commissioning services, as well as system start-ups. Our staff will travel anywhere in the world to help you get your system up and running. We start up hundreds of systems per year, and our licensed electricians on staff can pull permits as needed.
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Our Engineering and CAD department can create a wide range of documents, including functional specifications, software design documents, test manuals, O&M manuals, P&ID, system drawings, and network drawings. Drawings for FDA level documents are a particular specialty.
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Process Solutions software designers are equipped to handle any size job. We structure our program code to be easily read by both customers and engineers, making support and system upgrades fast and easy.
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Process Solutions builds over 3,000 panels per year. Our high-volume model makes our technicians experts in the field and provides our customers with an industry leading experience. Efficient manufacturing practices, mixed with automated manufacturing equipment, allows for quick and consistent job completion.
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Creation of custom designs for new and legacy systems. All drawings are template based using automatic CAD macros. Our techniques create an efficient design process with recognizable and easy to understand drawings.
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