Frozen ASRS — 9,200 pallet positions at −25 °C
Pallet shuttle ASRS in a –25 °C freezer with cold-rated drives, lubricants, and condensation control.
- Client
- Confidential — Frozen Food Co-Packer
- Location
- Iowa, USA
- Capabilities
- Turnkey Line Build · Process Engineering
The challenge
Co-packer needed to double cold-storage capacity without a new building. Existing reach trucks were running an extra shift and energy bills for the freezer warehouse were climbing 11% YoY.
What we built
AutoStore-style pallet shuttle in deep-lane racking. Drives use synthetic cold-rated lubricants, drives are cold-soak tested, and the dock interface includes an air-knife antechamber to manage condensation. Lighting drops to 5% when no operator is in-aisle.
Key equipment
- Cold-rated pallet shuttle
- Mecalux/Interlake racking
- Cold-soak tested drives
- Air-knife antechamber
From the floor
Illustrative image — representative of project scope; customer-identifying details have been removed.
Results
9,200 pallet positions live, two reach-truck shifts eliminated, and energy per pallet-day fell 40% from condensed lighting + sealed dock cycles.
See all 20 projects
Food & Beverage•2025Robotic palletizing cell — 2 shifts of manual stacking eliminated
Greenfield palletizing cell at end-of-line, sized for 60 cases per minute across 12 SKUs with quick-change tooling.
2Shifts of manual stacking replaced60 cpmCases per minute16 moProjected payback
Food & Beverage•2024AI vision defect detection — escape rate cut from 0.6% to 0.04%
Replaced rule-based blob analysis with a deep-learning model for label crease, low-fill, and cap-tilt defects on PET bottles.
0.04%Customer escape rate+9%OEE points gained<200 msPer-bottle decision time
Food & Beverage•2025Dairy bottling line retrofit — 18% throughput, 62% fewer rejects
Replaced a 1998-era controls stack with modern PLC + vision while keeping the existing filler and capper steel.
+18%Throughput-62%Reject rate11 wkProject lead time