Customer Success Story · Cold Chain
Leading Regional Frozen Food Distributor: AS/RS Cold Chain Storage Project
This automated storage and retrieval system (AS/RS) was custom-engineered for a major regional frozen-food distribution hub. Operating continuously at sub-zero temperatures, the solution achieved ultra-dense pallet storage and highly controlled, high-throughput dispatch flows.
Project Note: This is a real-world deployed project. The client's name has been anonymized to protect privacy. All capacity, throughput, cost-saving, and ROI figures below are actual operational acceptance data post-delivery.
Project Snapshot
This regional frozen-food hub serves as a central node for palletized seafood, ready meals, dairy products, and temperature-sensitive ingredients. The operation required rock-solid storage conditions, absolute pallet traceability, and high-volume dispatch capabilities without expanding the existing freezer footprint.
Operational Challenges
Prior to the upgrade, manual forklift operations in the extreme low-temperature environment resulted in long travel distances, inconsistent slotting, and severe pressure on available freezer floor space. The project focused on maximizing storage density while minimizing operator exposure time to the harsh environment and guaranteeing rapid outbound fulfillment.
- Rapidly growing inventory across multiple frozen-food product families straining existing capacity.
- Exorbitant energy and labor costs associated with manual handling and open freezer doors.
- Strict requirements for FIFO-controlled dispatch and 100% traceable pallet locations.
- Zero available land for future freezer footprint expansion.
AS/RS Solution & Configuration
The implemented solution seamlessly integrated high-bay pallet racking, stacker cranes, pallet conveyors, and an advanced Warehouse Control System (WCS). Receiving, storage, replenishment, and dispatch were structurally separated into defined zones, allowing automated transport equipment to operate smoothly and predictably 24/7.
- High-bay storage architecture engineered for continuous 1,000 kg pallet loads.
- Automated crane and conveyor transfer sequences eliminating manual handling inside the freezer.
- System-enforced FIFO allocation rules critical for temperature-sensitive stock.
- Automated barcode-based location confirmation at every single handoff point.
Actual Operational Impact
The delivered high-bay layout drastically increased storage density by fully capitalizing on vertical building volume, permanently removing repetitive forklift traffic from the freezer zone. The automated handling system established a rigid, highly efficient material flow from receiving directly through to dispatch.
- Capacity Jump: Successfully unlocked 10,368 pallet positions within the rigid 3,800 m² existing freezer footprint.
- Floor-Space Optimization: Freed up 44% of the active floor space required for the same pallet inventory volume.
- Throughput: Consistently achieves up to 120 automated pallet movements per hour at the conveyor interface.
- Inventory Control: Achieved 100% traceable pallet locations and flawless FIFO execution via WMS integration.
Return on Investment (ROI) Analysis
The following financial data is based on the client's actual operational settlement. Through structural cost reductions and operational efficiencies, the AS/RS delivered a compelling payback performance.
- RMB 1.30 million/year: Savings from avoiding a massive freezer expansion and terminating outsourced 3PL cold storage leases.
- RMB 0.85 million/year: Direct reduction in manual labor costs and significant energy savings from optimized freezer door operations.
- RMB 0.70 million/year: Savings generated by precise inventory control, eliminating expired goods, and drastically reducing handling damages.