MULTIFLEX Pallet Warehouse: High-Density Frozen Storage

Technology Overview

The MULTIFLEX warehouse system is a high-density automated storage and retrieval solution designed for unit load (pallet) handling, with a specific showcased application in the demanding environment of a deep freeze warehouse for frozen food. This technology addresses the critical need for maximizing storage capacity within a constrained footprint while maintaining high throughput in temperature-controlled logistics. It combines the density of multi-deep storage racking with the flexibility of autonomous shuttle carriers that operate within the storage channels. This case study highlights its implementation for Coppenrath & Wiese, a major European producer of frozen baked goods, to manage a diverse product portfolio with efficient, automated cold chain logistics.

How It Works

Core Principles

The core principle is decoupled horizontal and vertical movement. Instead of a single crane serving an entire aisle, the system uses lifts (vertical conveyors) to move pallets between the entry/exit level and the various storage levels. On each storage level, independent shuttle carriers operate on rails within the deep storage channels, responsible for putting pallets into storage locations and retrieving them from within the channel.

Key Components

Key components include: the high-bay racking structure with multi-deep storage channels on multiple levels; multiple autonomous shuttle carriers (one or more per level or group of channels); vertical lifts for transferring pallets between levels; inbound/outbound conveyors for automatic truck unloading and loading; and a material flow computer (WCS) that coordinates all devices. The system is installed by a main contractor like MFI.

Operational Process

1. Receiving: Pallets are automatically unloaded from trucks and conveyed to the warehouse infeed.
2. Put-away: A lift transports the pallet to the designated storage level. A shuttle carrier on that level receives the pallet, travels into the storage channel, and deposits it in an empty location.
3. Retrieval: Upon request, a shuttle carrier retrieves the required pallet from within its channel and brings it to the lift. The lift transports the pallet down to the dispatch level.
4. Shipping: The pallet is conveyed to the dispatch area and made ready for automatic truck loading.

Key Features & Capabilities

Channel-Bound Shuttle Operation: The use of shuttles within multi-deep storage channels is the defining feature. This allows for very dense storage within each aisle (multiple pallets deep) while maintaining independent access to each pallet position, offering a balance between high density and good selectivity.

High Throughput with Double Cycles: The system is engineered for high performance, capable of 200 double cycles (one storage and one retrieval operation) per hour. This is achieved through parallel processing: multiple shuttles can operate simultaneously on different levels, and lifts can operate independently.

Integrated Frozen Goods Handling: The entire system is designed and built to operate reliably in a deep freeze environment (-20°C to -30°C), with components (shuttles, lifts, conveyors) rated for low-temperature operation, ensuring consistent performance for cold chain logistics.

Advantages & Benefits

The primary benefit is the exceptional storage density achieved, maximizing capacity in a valuable and costly controlled-environment space. High throughput ensures fast product rotation, which is critical for fresh and frozen goods. Full automation eliminates manual labor in the harsh freezer environment, improving worker safety and operational efficiency. The turnkey approach with a single responsible contractor (like MFI) streamlined project execution and ensured accountability for system performance and integration with existing legacy systems.

Implementation Considerations

Implementing such a system is a major capital project requiring extensive planning. The building must provide sufficient height for the high-bay racking (12 levels in this case) and be structurally prepared. Integration with the higher-level Warehouse Management System (WMS) and existing site systems was noted as a critical success factor. The technology is particularly suited for high-volume, high-SKU count pallet operations where space optimization and throughput are paramount.

Use Cases & Applications

Ideal For

This system is ideal for large-scale food & beverage producers, distributors, and logistics providers operating temperature-controlled warehouses, especially for frozen or chilled products. It is also suitable for any industry requiring high-density, high-throughput pallet storage.

Common Applications

Its most common application is in large automated cold storage warehouses for frozen foods, ice cream, ready meals, and pharmaceuticals. It can also be used in ambient temperature distribution centers for consumer goods, automotive parts, or other palletized inventory.

Vendor Solutions

| Vendor/Partner | Product/Solution | Key Features | |--------|------------------|--------------| | DAMBACH | MULTIFLEX Warehouse System | Shuttle-based channel storage, high capacity & throughput, designed for cold storage | | MFI (System Contractor) | Turnkey Warehouse Implementation | Full responsibility for planning, installation, commissioning, and system integration |

Performance Metrics

The provided metrics are central to the system's value: 20,000 pallet spaces and 200 double cycles per hour. These quantify the high-density storage capacity and the operational throughput. The successful on-time commissioning despite a tight schedule is also a key performance indicator of project execution.

Conclusion

The MULTIFLEX warehouse system demonstrates how advanced shuttle-based automation can solve complex logistics challenges, such as storing a diverse frozen goods portfolio with maximum efficiency. For companies like Coppenrath & Wiese, investing in this technology provided a future-proof solution that maximizes space utilization, ensures high throughput, and integrates seamlessly into existing operations. The project's success underscores the importance of a collaborative, solution-oriented partnership between the end-user, the system integrator, and the technology provider. For any operation facing space constraints and high volume in temperature-controlled or ambient storage, the MULTIFLEX system represents a leading-edge automated storage solution.