Fully Automated High-Bay Frozen Warehouse (-25°C)

Project Challenge

The project involved a 30-meter high automated storage and retrieval system (AS/RS) warehouse. The main challenges were maintaining a uniform -25°C temperature throughout the vast vertical space, minimizing air infiltration from frequent pallet movements, and integrating the refrigeration system with the warehouse management system (WMS).

Solution Provided

We installed a powerful ammonia (NH3) refrigeration system, known for its high efficiency in large-scale, low-temperature applications. A specialized air distribution system with high-throw air coolers was designed to ensure consistent temperature from floor to ceiling. High-speed insulated doors and air curtains were installed at the conveyor openings to minimize energy loss. The refrigeration controls were fully integrated with the client's WMS for optimized performance.

Project Results

The warehouse maintains a temperature variance of less than 1.5°C across the entire 30-meter height. The automated integration allows the refrigeration system to enter low-energy modes during periods of inactivity, contributing to significant operational savings. Air infiltration losses were reduced by over 70% compared to a conventional design.