{"id":30991,"date":"2024-09-17T08:00:01","date_gmt":"2024-09-17T13:00:01","guid":{"rendered":"https:\/\/www.cisco-eagle.com\/blog\/?p=30991"},"modified":"2025-08-04T10:46:19","modified_gmt":"2025-08-04T15:46:19","slug":"keeping-up-with-rising-cold-storage-requirements","status":"publish","type":"post","link":"https:\/\/www.cisco-eagle.com\/blog\/2024\/09\/17\/keeping-up-with-rising-cold-storage-requirements\/","title":{"rendered":"Meeting the Demands of Cold Storage"},"content":{"rendered":"<p><img decoding=\"async\" style=\"width: 100%; max-width: 700px; height: auto; margin-bottom: 2px;\" src=\"https:\/\/images.cisco-eagle.com\/blog\/wp-content\/uploads\/2024\/09\/Large-Storage-with-Racking.jpg\" alt=\"pallet rack in cold storage facility\" \/><\/p>\n<p>In the cold and frozen food sector, tremendous growth combined with a serious shortage of capacity is severely constraining companies today. \u201cThe frozen food market is currently experiencing remarkable growth, with its global value soaring to $265 billion. In the U.S. alone, new frozen food sales have impressively surpassed the $72 billion mark,\u201d states Rick Kingery in the Colliers\u2019 article \u201cCapitalizing on the $265 Billion Frozen Food Market: Cold Storage\u2019s Crucial Role.\u201d<\/p>\n<p>Adding to the challenge, \u201cWe estimate the U.S. will need up to 100-million-square-feet of additional cold storage space in the coming years,\u201d states Marty Khait in an article posted on the Refrigerated &amp; Frozen Foods Magazine website, \u201cThe Cold Reality: Why America\u2019s Cold Storage Capacity is Running Low.\u201d<\/p>\n<p><!--more--><\/p>\n<aside style=\"padding: 10px 20px 15px 25px; margin-bottom: 50px; border-radius: 15px; border: 2px solid #E4DDDD; margin: 4px 10px 4px 10px; box-shadow: 0 4px 8px 0 rgba(0, 0, 0, 0.2), 0 6px 20px 0 rgba(0, 0, 0, 0.19);\" data-type=\"summary\">\n<h4>TL;DR \u2013 Cold storage expansion: Rack systems &amp; shuttle solutions<\/h4>\n<p>With cold storage demand outpacing supply, facilities must maximize capacity without excessive build costs. This post covers smart rack strategies like drive-in, pushback, and pallet flow systems, and explores how pallet shuttles can semi-automate deep lane storage. It also explains why rugged structural steel racks are critical for withstanding freezer conditions and forklift impact.<\/p>\n<\/aside>\n<h3>Utilize new technologies for efficient systems<\/h3>\n<p>For cold and frozen storage professionals, one solution to this dilemma might be looking at the racking and storage systems currently in place in your facilities. Depending on the age of your facility, there are several things you can do that would increase storage density. This includes space-efficient racking systems along with advanced technology like pallet shuttles, which semi-automates high-density storage with specialized carts to facilitate the seamless movement of pallets within the storage framework.<\/p>\n<h4>Automating cold storage<\/h4>\n<p>At the forefront of this combination of rack and technology design are enhanced warehouse efficiency and storage capabilities to meet the market\u2019s urgent need for cold and frozen storage.<\/p>\n<p>For businesses seeking optimal warehouse management, <a href=\"http:\/\/www.steelking.com\">Steel King<\/a> offers a semi-automated pallet shuttle technology as a turnkey solution. The pallet shuttle is a lithium-ion powered Pallet Runner\u2122 deep lane storage system from Automha Americas, a pioneering pallet shuttle provider, that efficiently moves pallets in and out of high-density storage lanes, creating increased storage density in an existing space.<\/p>\n<p>The system is particularly suited to applications with high-volume SKUs, as pallets are loaded into the system by lift truck and transported into deep lanes by the Pallet Runner cart. Once the load is positioned, the cart returns to the front of the system to receive the next pallet. The lift truck operator travels only between the load source and lane entry, and the cart does the rest. This maximizes productivity and minimizes travel distance for both product loading and unloading.<\/p>\n<p>\u201cThe seamless integration of the pallet shuttle technology with the pallet rack systems will offer warehouses and distribution centers increased automation, efficiency, flexibility, productivity, and safety\u201d said Don Heemstra, VP of Sales and Marketing for Steel King.<\/p>\n<blockquote><p><em><strong>Read more:<\/strong> <a href=\"https:\/\/www.cisco-eagle.com\/blog\/2024\/08\/08\/checklist-what-to-discover-before-your-automation-project\/\">Warehouse automation planning checklist<\/a><\/em><\/p><\/blockquote>\n<h4>Selecting and optimizing cold storage racking<\/h4>\n<p><iframe loading=\"lazy\" src=\"https:\/\/www.cisco-eagle.com\/video\/frame.aspx?id=968\" width=\"640\" height=\"360\" frameborder=\"0\" scrolling=\"no\"><\/iframe><\/p>\n<blockquote><p><em>Employee-Owner Landry shows you how to take key measurements for the specification of selective pallet rack\u00a0<\/em><\/p><\/blockquote>\n<p>With costs per square foot for a cold storage facility up to three times that of a regular warehouse, choosing the right system is essential for efficiency and cost-effectiveness. Toward this effort, racking OEMs offer multiple types of cold storage pallet racking solutions including drive-in, pushback, pallet flow, and selective.<\/p>\n<p>According to Heemstra, the right type for each storage facility is based on the requirements for throughput, selectivity, workflow, potential expansion, and other factors. All types of cold storage racks can be designed to maximize storage capacity, so construction and installation costs are not excessive.<\/p>\n<h5>Which rack you choose matters<\/h5>\n<p><a href=\"https:\/\/www.cisco-eagle.com\/category\/792\/steel-king-tubular-racks\">Selective racking<\/a> is the most common type of pallet storage and allows easy and immediate access to any pallet as storage is only one pallet deep. Selective racking can also be used for double deep storage, stacking pallets two-deep accessible via reach truck.<\/p>\n<p>However, <a href=\"https:\/\/www.cisco-eagle.com\/category\/3036\/drive-in-racks\">drive-in racking<\/a> is often the choice for cooler and freezer facilities, as these systems can accommodate up to 75% more pallets than selective racking. High-density storage is provided by allowing pallets to be stored multiple positions deep, which reduces the space needed for aisles and makes the rack a popular choice.<\/p>\n<div style=\"padding: 20px; border-radius: 15px; border: 2px solid #E4DDDD; margin: 4px 10px 4px 10px; box-shadow: 0 4px 8px 0 rgba(0, 0, 0, 0.2), 0 6px 20px 0 rgba(0, 0, 0, 0.19);\">\n<h4>Industry examples &#8211; Discovering the right rack solutions<\/h4>\n<h5>Coloma Frozen Foods<\/h5>\n<p>Coloma Frozen Foods was outsourcing its frozen storage to commercial facilities spread over a 20-mile radius from their location and among four inter-company locations for production, frozen storage, and repacking \u2013 a costly, inefficient process.<\/p>\n<p>Looking to maximize frozen storage efficiency and repacking capability, the company consolidated its frozen storage capacity into a new 90,000 sq. ft. freezer space that included 75,000 sq. ft. of racked freezer space utilizing drive-in racking. With the drive-in rack, Coloma was able to store up to 75% more pallets than selective racking in the same space and expects to save about $150,000 to $200,000 a year in reduced labor, management, transportation, energy, and maintenance costs.<\/p>\n<h5>Manfredi Cold Storage<\/h5>\n<p>Manfredi Cold Storage expanded its Kennett Square, PA facility and installed an exceptionally rugged drive-in rack. The racking is specially designed for high-traffic and cold-temperature cooler\/freezer installations.<\/p>\n<p>The distributor handles fruit, vegetables, and food stuffs from 22 countries, in a blast freezer environment in its 400,000 total sq. ft. facility. Steel King\u2019s drive-in rack allowed Manfredi to move 25,000 pallets in 150-200 truckloads daily to supply grocery stores, club stores, distribution centers, and the food service industry quickly and efficiently.<\/p>\n<\/div>\n<p>Another option utilized by leading food companies to optimize cold storage capacity and longevity includes <a href=\"https:\/\/www.cisco-eagle.com\/category\/3044\/pushback-rack\">pushback racking systems<\/a> that accommodate multiple-depth pallet storage, commonly two to five deep. In these systems, access to the pallets can be on one or both sides of the racking system. Because of the depth options, pushback racking can hold up to 90% more storage than a selective system. Pallets are loaded onto wheeled carts at each level of the racking. Inclined rails allow pallets to roll to the front of the rack as the most forward pallet is removed.<\/p>\n<p><a href=\"https:\/\/www.cisco-eagle.com\/category\/3043\/pallet-flow-racks\">Pallet-flow racking systems<\/a>, like pushback systems, take advantage of gravity to ensure that pallets are easily accessible from the front of the racking. But in these high-density, labor-saving systems, pallets are loaded on one side and unloaded on the other, assuring first-in, first-out (FIFO) handling. Forklifts are required only for the initial loading and final unloading.<\/p>\n<h4>Structural integrity considerations for cold room storage racks<\/h4>\n<p><img decoding=\"async\" style=\"width: 100%; max-width: 250px; height: auto; margin-bottom: 1px; margin-top: 2px;\" src=\"https:\/\/images.cisco-eagle.com\/blog\/wp-content\/uploads\/2024\/09\/Steel-King-rack-system-in-cold-storage-warehouse.jpg\" alt=\"loaded cold storage pallet rack\" \/><br \/>\nIn cooler and freezer applications, the rack must withstand some of the greatest forklift abuse in warehouse material handling due to the confined space, slick surfaces, and cold temperatures that slow driver reflexes and make impact more frequent. This can compromise the structural integrity of racking systems.<\/p>\n<p>To prevent rack damage, Heemstra recommends using hot-rolled steel to manufacture the uprights and beams of structural steel racking. Horizontal and diagonal bracing and heavy-duty foot protectors can further enhance the durability of the racking in cold environments.<\/p>\n<p>As one example in the industry, for greater overall strength and rigidity, Heemstra recommends a pallet racking manufactured from high C-channel structural steel and ideal for use in a cold storage racking system. A heavy-duty lower horizontal brace and welded foot protector safeguard these areas that are prone to forklift damage. Since the system is modular, it can be designed to easily accommodate changing or expanding storage needs in cold storage facilities.<\/p>\n<p>While such construction creates a higher up-front cost for structural storage racks, that can be more than offset by lower maintenance costs, greater safety for people working in the facilities, increased load capacities, and resistance to seismic forces.<\/p>\n<div style=\"padding: 20px; border-radius: 15px; border: 2px solid #E4DDDD; margin: 4px 10px 4px 10px; box-shadow: 0 4px 8px 0 rgba(0, 0, 0, 0.2), 0 6px 20px 0 rgba(0, 0, 0, 0.19);\">\n<div class=\"row\">\n<div class=\"col-sm-4\">\n<p><a href=\"https:\/\/www.cisco-eagle.com\/uploads\/brochures\/pallet-rack-guide.pdf\"><img decoding=\"async\" style=\"float: right; width: 100%; max-width: 200px; height: auto; margin-left: 20px; margin-right: 18px;\" src=\"https:\/\/images.cisco-eagle.com\/blog\/wp-content\/uploads\/2021\/08\/PalletRackGuide.jpg\" alt=\"Use the Cisco-Eagle pallet rack guide\" \/><\/a><\/p>\n<\/div>\n<div class=\"col-sm-8\">\n<div class=\"row\">\n<h3>Download our Pallet Rack Guide<\/h3>\n<p>Pallet rack enhances your warehouse and improves overall facility performance when correctly specified, laid out and installed for the right load in the right positions. Check out our guide to specifications, styles, accessories and applications with expert tips from our employee-owners.<\/p>\n<p>You&#8217;ll find quick, useful information on racks and how you can use them more effectively.<\/p>\n<h4><a href=\"https:\/\/www.cisco-eagle.com\/uploads\/brochures\/pallet-rack-guide.pdf\"><strong><em>Download the guide today<\/em><\/strong><\/a><\/h4>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n","protected":false},"excerpt":{"rendered":"<p>In the cold and frozen food sector, tremendous growth combined with a serious shortage of capacity is severely constraining companies today. \u201cThe frozen food market is currently experiencing remarkable growth, with its global value soaring to $265 billion. In the U.S. alone, new frozen food sales have impressively surpassed the $72 billion mark,\u201d states Rick [&hellip;]<\/p>\n","protected":false},"author":21585,"featured_media":0,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[6],"tags":[],"series":[],"class_list":["post-30991","post","type-post","status-publish","format-standard","hentry","category-pallet-rack"],"acf":[],"aioseo_notices":[],"publishpress_future_action":{"enabled":false,"date":"2027-04-26 07:14:05","action":"change-status","newStatus":"draft","terms":[],"taxonomy":"category","extraData":[]},"publishpress_future_workflow_manual_trigger":{"enabledWorkflows":[]},"_links":{"self":[{"href":"https:\/\/www.cisco-eagle.com\/blog\/wp-json\/wp\/v2\/posts\/30991","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.cisco-eagle.com\/blog\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.cisco-eagle.com\/blog\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.cisco-eagle.com\/blog\/wp-json\/wp\/v2\/users\/21585"}],"replies":[{"embeddable":true,"href":"https:\/\/www.cisco-eagle.com\/blog\/wp-json\/wp\/v2\/comments?post=30991"}],"version-history":[{"count":32,"href":"https:\/\/www.cisco-eagle.com\/blog\/wp-json\/wp\/v2\/posts\/30991\/revisions"}],"predecessor-version":[{"id":32633,"href":"https:\/\/www.cisco-eagle.com\/blog\/wp-json\/wp\/v2\/posts\/30991\/revisions\/32633"}],"wp:attachment":[{"href":"https:\/\/www.cisco-eagle.com\/blog\/wp-json\/wp\/v2\/media?parent=30991"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.cisco-eagle.com\/blog\/wp-json\/wp\/v2\/categories?post=30991"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.cisco-eagle.com\/blog\/wp-json\/wp\/v2\/tags?post=30991"},{"taxonomy":"series","embeddable":true,"href":"https:\/\/www.cisco-eagle.com\/blog\/wp-json\/wp\/v2\/series?post=30991"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}