Agile Cold Storage Distribution Center

Project Overview

Agile Cold Storage was founded in 2020 by cold storage industry veteran Don Shanel, specializing in third-party cold storage services primarily for food manufacturers. The company handles order picking and pulling for food distributors across the country with a significant focus on export markets worldwide.

The automation project was driven by the need to maximize pallet capacity within the available building footprint while maintaining operational efficiency in a demanding cold storage environment. The facility serves food manufacturers who require reliable, temperature-controlled storage and distribution services.

Swisslog was selected as the automation partner based on shared values, access to management and technical resources, and the commitment to world-class technology implementation.

Technical Solution

Automated Storage and Retrieval System (ASRS)

The facility features a comprehensive Swisslog ASRS with six independent crane aisle modules. Each crane aisle operates as its own individual module with dedicated inbound and outbound stations, ensuring operational isolation and reliability. The system stores 48,000 pallets within a 110,000 square foot footprint.

Key Features

The ASRS configuration with six independent crane aisles provides operational redundancy and reliability, ensuring that activities in one aisle don't affect others. This modular design gives customers confidence that their orders will be ready when called.

The SynQ software integration creates a seamless control environment, managing all aspects of inventory location selection and order fulfillment. The system's energy-efficient design consumes approximately half the expected energy, contributing to significant operational cost savings.

Results & Benefits

The automated system tripled storage capacity compared to conventional cold storage methods, achieving 48,000 pallets in 110,000 square feet versus 20,000 pallets in 150,000 square feet with conventional 2-deep reach systems.

Energy consumption was reduced by 50% compared to initial expectations, providing substantial cost savings and environmental benefits. The reliable system performance built confidence among employees, customers, and investors, establishing a foundation for future expansion.

Operational efficiency improvements and long-term cost control were achieved through the automated solution, enabling Agile to provide superior service to food manufacturers and global export markets.

Challenges & Solutions

The primary challenge was achieving the required pallet capacity within the limited available building footprint. The solution involved implementing Swisslog's high-density ASRS system, which optimized vertical space utilization and storage density far beyond conventional cold storage methods.

The successful startup and reliable operation of the automated system demonstrated the effectiveness of the partnership approach and world-class technology selection, establishing a model for future cold storage automation projects.

System Integrator

Swisslog provided comprehensive automation solutions including cranes, conveyors, and software from top to bottom. The partnership was characterized by excellent access to the right people and management, shared values between the organizations, and commitment to world-class technology implementation.

The reliability and flawless operation of the Swisslog system contributed significantly to building confidence across all stakeholders and established a strong foundation for future collaborative projects.