Cold storage racks are essential logistics solutions designed to store products like food and medicines at controlled temperatures, ensuring the preservation of their properties. Typically constructed from stainless steel, these racks are robust enough to withstand cold and freezing environments. Their dual purpose is to maximize warehouse space by achieving:
- High storage capacity
- Energy efficiency through optimal cold distribution across numerous pallets
In the following sections, we’ll explore the most suitable storage systems for cold storage facilities and their unique features.
Advantages of Cold Storage Racks
- Premature product deterioration
- Loss of product properties
- Growth of harmful bacteria and microorganisms
Cold stores can implement various storage systems, including:
- Direct access systems: Standard pallet racks that allow operators to access all SKUs directly, although they may not fully utilize the available surface area.
- High-density racking systems: These maximize storage capacity but do not provide direct access to all items.
How to Choose the Right Cold Store Racking
When designing a cold storage warehouse, it's essential to select the most suitable system that:
- Maximizes storage capacity
- Streamlines access to goods
- Minimizes staff presence in the area
- Facilitates strict control over stored products
However, this is not as straightforward as it may appear. Consider these parameters when deciding on a storage system:
- Quantity of goods to be stored
- Size of the cold store
- Space required for cold generators
- Goods inflows and outflows
- Product seasonality
- Water drainage systems and pavement slopes (to manage condensation)
At this point, it is essential to assess the advantages and disadvantages of each storage system. While many companies opt for non-automated solutions due to their simplicity and lower initial costs, these options can subject operators to extreme temperatures and elevate the risk of errors in tasks such as replenishment and order picking. On the other hand, automated cold-storage warehouses, although requiring a higher upfront investment, bring considerable benefits, including:
- Reduced or minimal staff presence
- Better utilization of space and height
- Improved traceability control
- Greater productivity
Most Common Cold Store Racking
Here are some frequently used cold storage racks along with their benefits:
Pallet Racks
In cold stores, a variety of pallet racking systems can be implemented, including:
- Standard pallet racks
- Drive-in/drive-thru racks
- Flow racks
- Push-back racks
Different storage systems cater to specific logistics needs:
- Drive-in pallet racks maximize storage capacity.
- Live pallet racks or push-back racks enhance agility by speeding up pallet retrieval and forklift movement.
- Standard pallet racks allow direct access to goods, ideal for diverse product storage and picking.
In medium to large cold storage facilities, a combination of these systems can be used for different products and operations.
Racks on Mobile Bases
Mobile pallet racking systems are mounted on mobile bases that slide laterally, offering direct access to all SKUs. This compact storage solution is particularly beneficial for cold and freezer stores, as it optimally distributes cold air among a larger number of pallets, reducing costs per pallet. During downtime, better air circulation is ensured through a parking option that maintains equidistant aisles.
Pallet Shuttle System
This high-density storage solution employs a shuttle for automatic movements within the racks. It operates in two modes:
- Semi-automated Pallet Shuttle: An operator places the load on the rails, and the shuttle moves it to a designated location within high-density racks. This is ideal for cold stores with numerous pallets per SKU.
- Automated Pallet Shuttle: Stacker cranes or transfer cars move goods to the appropriate channels. These racks can reach heights of up to 40 meters, making them suitable for medium- and high-rise warehouses with diverse SKUs.
Both mobile base racks and the Pallet Shuttle system enhance storage capacity, but the Pallet Shuttle system offers greater speed for pallet entries and exits.
Automated Storage and Retrieval Systems (AS/RS) for Pallets
Automated Storage and Retrieval Systems (AS/RS) utilize single or double-deep racks and stacker cranes to manage warehouse goods efficiently. They handle larger quantities of products, enhancing pallet insertion and removal speed. These systems reduce the cooling space required, resulting in energy savings, and offer systematic inventory control, ensuring real-time management and compliance with turnover and traceability standards.
Automated Miniload Warehouse for Boxes
Boxes can be efficiently managed in cold stores using AS/RS for boxes. Similar to pallet systems, these setups consist of racks storing boxes and miniload stacker cranes that handle goods automatically. This solution maximizes space utilization and provides excellent access to products. As with pallet systems, automation boosts productivity and ensures complete security and protection for the items.
Cold Stores of the Future
Racks play a crucial role in the effective management of merchandise in cold storage warehouses. They should be designed to optimize space, ensuring maximum storage capacity and facilitating easy handling of goods.