FOOD MANUFACTURING ALERT SYSTEM

HelloFresh, a global leader in meal-kit food manufacturing and distribution, required a robust on-premise food manufacturing alert system to enhance safety, communication, and operational efficiency across its 14 food processing facilities located in NJ, TX, CA, CO, GA, AZ, and IL—ranging from 25,000 to 450,000 square feet. As a high-volume food production environment, each site needed a scalable wireless paging and emergency notification solution capable of supporting routine daily voice announcements, staff coordination, and real-time audio-visual emergency alerts. The system had to deliver reliable, facility-wide coverage with the following core capabilities

Visiplex’s wireless food manufacturing alert system was deployed using a centralized wireless paging base station installed in the facility’s main office. A dedicated six-button switch module at the manager’s desk provided fast, one-touch activation of multilingual, pre-recorded emergency voice messages—ensuring rapid response during critical events. The wireless base station was also integrated with a NOAA digital weather radio receiver, enabling real-time severe weather alerts for local storm and tornado warnings.

To deliver reliable, plant-wide coverage, the solution included wireless audio-visual PA speakers strategically installed throughout the production environment—including freezers, coolers, conveyor lines, break rooms, and muster points. This ensured clear emergency voice paging in all high-noise and temperature-controlled zones. For enhanced visibility and ADA compliance, the system utilized LED message boards that provided bright, high-contrast visual alerts during emergency notifications.

Specialized wireless controllers with dry-contact relays allowed seamless integration with the facility’s externally monitored security alarm panel, enabling remote, simultaneous activation of the Visiplex alert system.

During daily operations, the system supports live voice announcements, shift-change communications, and routine production updates, while LED message boards display synchronized time and high-visibility operational messages across the facility.

All components were engineered with built-in battery backup, ensuring continuous operation during power failures or grid instability—critical for maintaining uninterrupted emergency communication in food manufacturing environments.

Thanks to its scalable, modular wireless architecture, each of the 14 HelloFresh facilities was equipped with a complete food manufacturing alert system without the need for trenching, conduit installation, or disruptive wiring. Visiplex technicians completed full system testing, commissioning, and on-site staff training to guarantee reliable, seamless performance.

Optimized Wireless Food Manufacturing Alert System – The fully integrated wireless audio-visual emergency alert system was successfully deployed across all 14 HelloFresh food manufacturing facilities, significantly improving site-wide safety, emergency preparedness, and real-time communication with staff and visitors. This scalable solution streamlined operations while delivering the following key capabilities: