Automated cold storage systems offer significant benefits over conventional systems.

Thinking about automating your cold storage systems? Don't just think about it, start acting now.

Cold Storage systems pose several challenges, The solutions of yesterday...Advanced solutions - such as automation are key to maintaining a competitive edge.  Conventional solutions are becoming increasingly obsolete, especially for businesses that are growing or are poised to grow.

At Daifuku Intralogistics America, we're global leaders in designing and implementing automated solutions for all types of environments, including cold storage. Read on to learn more about the importance of cold storage systems and how automation can take your business to new heights.

Cold Storage Systems: What to Know

Cold storage systems are important because they adequately preserve temperature-sensitive products, which may include foods, pharmaceuticals, chemicals and more. Cold storage systems are crucial for preserving products and extending shelf life.  Automating storage and retrieval for cold storage provides significant benefits, primarily by mitigating the challenges inherent to extreme temperature environments.

Key Benefits of Automating Cold Storage Systems

Key benefits fall into three categories: operational efficiency, cost reduction, and safety compliance.

Warehouses need to adapt to evolving technologies to stay relevant in a competitive environment. One emerging technology to support cold storage is automation. So, what's the difference between automated solutions and conventional solutions in this environment?

Operational Efficiency and Productivity

Increased Throughput: Automated Storage and Retrieval System can operate continuously without breaks which are required for human labor in the extreme cold.  Reduced storage/retrieval cycle times and greater utilization lead to higher overall volume of product movement for system resources.

Maximized Space Efficiency: AS/RS Unit Load is a high-density pallet storage system designed to maximize vertical pallet space with fast, accurate retrieval in a compact footprint. Daifuku’s AS/RS systems can store products to rack heights of up to 131 ft and are ideal for cold storage applications.  This compares to conventional storage systems which rarely go above 40 feet.  This vertical integration maximizes the use of costly refrigerated space which is significantly more expensive to build and maintain than ambient space.  

Inventory Accuracy and Traceability: The Automated Storage and Retrieval System significantly reduces errors in inventory control through the integration of every item’s movement in real time with the Warehouse Management System (WMS). This ensures better product rotation, full cold chain compliance, and traceability for perishable goods.

Cost Reduction and Energy Savings

Automation for cold storage can be a significant investment relative to more conventional systems; however, the long-terms efficiency and cost savings benefits lead to a significant return on investment.

Reduced Labor Costs: We know that managing manual labor in a harsh cold storage environment can be challenging.  There are typically specific time intervals and limits that an operator can work in the cold storage environment.  Freezer environments can be harsh.  Automation will reduce the need for labor inside cold storage which will reduce direct labor costs as well as the cost associated with high turnover which is common in these environments.

Reduced Energy Consumption: High density automated storage reduces the overall building cube in comparison to more conventional non-automated systems.  Conventional environments require wider aisles for human-operated equipment to safely travel through the warehouse.  Less labor reduces the number of door openings and introduction of ambient air.  These inherent characteristics of automated cold storage systems will help reduce energy costs by improved temperature control and less cubic space to refrigerate.

Minimized Product Damage: Automated handling equipment is always more precise and consistent compared to manual methods. This will lead to a reduction in rack and product damage which leads to overall reduced operating costs.

Employee Safety and Product Integrity

Improved Employee Safety: Automated systems reduce the number of employees and minimize their exposure to cold temperatures.  Systems can be monitored and managed from ambient control rooms.  These systems lead to overall improved safety outcomes for cold storage.

Consistent Product Quality: Automation for cold storage ensures that goods are accurately tracked and handled on a consistent basis, which leads to improved product quality.  Reduced temperature fluctuations are key to maintaining product quality and integrity for temperature sensitive items like foods and pharmaceuticals.

Regulatory Compliance: The core principle of FDA Cold Chain Regulations it to maintain product identity, strength, quality, and purity throughout the supply chain. The key benefits derived from automated solutions include enhanced traceability, improved temperature control, and rigorous record-keeping.  

Automation Solutions to Consider Incorporating Into Your Cold Storage Environment

Now that we've discussed some of the key benefits of incorporating automated solutions into your cold storage environment, let's take a closer look at some of the solutions that you might consider. Here's a look:

AS/RS systems

Automated storage and retrieval systems (AS/RS) are specifically designed to work in cold storage environments, with the ability to operate at temperatures as low as -30 degrees Fahrenheit. Custom solutions can be designed to work in environments that are even colder. AS/RS systems help maximize storage density and can reduce energy and labor costs. AS/RS systems also boost inventory management efforts by allowing precise tracking and management of inventory to help ensure that products are appropriately stored and then retrieved from specific locations.

ARUP Laboratories is a good example of a Daifuku client that needed to use AS/RS systems in its cold storage system to maintain growth. The company utilized a mix of automated storage solutions, conveyors and sortation technologies to improve chain of custody quality in its cold storage environment, which is set to -20 degrees Fahrenheit. Learn more about ARUP Laboratories' challenge and solution here.

Sorting Transfer Vehicles

Sorting Transfer Vehicles, or STVs, are other automated solutions that can operate in cold storage environments. However, it's important to note that only freezer-rated models are applicable to such situations to ensure that various components aren't damaged by cold temperatures or condensation.

These transfer vehicles can provide high-throughput material handling and work in conjunction with AS/RS. Similar to STVs, the Automated Pallet Monorail runs on a rail-guided track and serves as a fast, flexible and easy way to transport materials from one area of a facility to another.

Contact Daifuku Today

From safeguarding workers to streamlining efficiency, automation is a game-changer for cold storage environments — and those who don't adopt such solutions will likely eventually fall behind in a competitive landscape.   "Time is money" may be one of the oldest clichés, but it's one hundred percent accurate in the warehouse setting. Any efficiency improvements in handling, storing and retrieving goods will directly result in faster order preparation and, ideally, greater profitability. The efficiency improvements can also represent many real advantages for your warehousing operation.

As global leaders in developing and manufacturing automated solutions, Daifuku has the solutions that can help take your cold storage environment to new, automated heights. Daifuku is credited with designing the world's first AS/RS in 1966 and remains the market leader with tens of thousands of installations worldwide. We've also worked to continuously improve AS/RS technology and move this equipment forward to offer more benefits to our customers.

Whether you're seeking AS/RS or other automated solutions for your cold storage environment, Daifuku can help. Contact us today to learn more about our industry-leading solutions.