Case Study 2 – Cold Storage Solutions
High-Density AS/RS in Sub-Zero Environments
Advanced automated storage system engineered for reliable operation in freezer warehouses at −18°C, combining specialized robotics with cold-resistant components.
Project Overview
This project involved the deployment of a high-density automated storage and retrieval system (AS/RS) in a freezer warehouse environment operating at sub-zero temperatures. The primary goal was to significantly increase storage capacity while maintaining stable, reliable automated operations under low-temperature conditions.
The solution integrates four-way shuttle robots and vertical lifts, delivering flexible storage zoning, efficient pallet movement, and adaptability to fluctuating operational demand.
System Configuration
Automation Equipment for Cold Storage
12 Four-Way Shuttle Robots
Specialized shuttle robots designed to operate reliably in sub-zero temperature environments with enhanced cold-resistant components.
8 Vertical Lifts
Cold-weather optimized vertical lifts enabling precise pallet transfers between floors in freezer conditions.
2,315 lb Maximum Pallet Weight
Heavy-duty system capable of handling substantial loads in challenging low-temperature environments.
21 ft Total Warehouse Height
Optimized vertical space utilization designed for freezer warehouse operations.
8,000+ Pallet Storage Capacity
High-density cold storage solution maximizing capacity in temperature-controlled environments.
Specialized for Extreme Conditions
Operating Environment
The system operates within a freezer warehouse maintained at approximately −0.4 °F (−18 °C). All automation components are designed to maintain operational stability and mechanical reliability in sustained low-temperature conditions.
This environment places additional demands on drive systems, batteries, controls, and structural components, all of which are addressed through system-level design and component selection.
Key Features
- • Cold-resistant mechanical components engineered for consistent performance at −18 °C
- • Specialized battery systems optimized for low-temperature operation and extended runtime
- • Enhanced drive systems with cold-weather lubricants and materials
- • Robust control systems designed to maintain accuracy and responsiveness in freezer conditions
- • Flexible storage zoning enabling efficient organization of diverse frozen products
- • Adaptable to demand fluctuations supporting varying throughput requirements
Cold Storage Technical Excellence
- • Proven reliability in continuous sub-zero operations
- • Minimized human exposure to extreme cold environments, improving safety
- • Energy-efficient operations reducing door openings and minimizing temperature fluctuations
- • Consistent pallet positioning accuracy even in challenging temperature conditions
- • Scalable architecture allowing future expansion while maintaining cold chain integrity
Project Outcome
The cold storage AS/RS implementation successfully delivered a reliable, high-capacity automated solution for sub-zero warehouse operations. The system demonstrated exceptional stability and performance under extreme temperature conditions, significantly increasing storage density while reducing labor exposure to freezer environments.
This project showcases the feasibility and benefits of deploying advanced automation in challenging cold storage applications, providing a scalable foundation for future expansion.