Cold Storage Automation offers significant advantages for facilities that operate in the cold chain. These include faster fulfillment, fewer errors and more efficient energy use.
With automation, people and equipment don’t need to enter the facility. This decreases labor costs, as well as the risk of human injuries and damage to products.
Temperature-Controlled Warehousing
Many foods, medicines and consumer goods require cold storage facilities to preserve their quality and protect them from environmental hazards. This translates into a complex, regulated supply chain with meticulous temperature monitoring and strict product quality assessments. Despite these high standards, any disruptions can impact cooling systems and lead to spoilage or contamination, thus necessitating the implementation of innovative material handling solutions that can keep up with demand without jeopardizing products’ integrity.
The use of automation in cold storage enables higher throughput and more efficient operations by speeding up the processing of orders, reducing labor costs and optimizing energy management. Autonomous mobile robots (AMRs) and pallet shuttles, which are equipped with special batteries for working in cold environments, help reduce the need for workers to be in these rooms and limit their exposure to the freezing conditions.
Cold storage automation increases product selection and improves order fulfillment by allowing workers to focus on more critical tasks and decreasing the time spent in cold rooms, minimizing the risk of error. Additionally, cold storage automation provides enhanced hygiene in logistics processes by removing the need for human hands in unfavorable environmental conditions. These advantages contribute to lower waste, quicker inventory turnaround and a more reliable delivery process. This is especially important in the e-commerce sector, where customers demand fresher goods that are ready to ship at a moment’s notice.
Automated Storage and Retrieval Systems (AS/RS)
Automated Storage and Retrieval Systems (AS/RS) are computer-controlled systems that efficiently store and retrieve loads from specific locations. They’re commonly used in warehouses, manufacturing units and distribution centers, including cold storage, automotive, food and beverage, pharmaceutical manufacturing and e-commerce operations. There are a number of options for AS/RS, ranging from unit-load systems that handle pallets of parts to high-speed carousel systems that store individual items in bins or boxes. Each type of AS/RS system is designed for different types of loads, so it’s important to assess your facility’s needs and choose the best solution.
AS/RS systems can be incredibly efficient, increasing warehouse productivity and efficiency. They’re also able to reduce operational costs through space optimization and energy savings, as well as by reducing labor costs associated with repetitive, manual tasks. These savings can add up to a significant return on investment for businesses over the long term.
Some signs that it might be time to consider AS/RS in your warehouse include limited storage space, rising energy costs, frequent picking errors and a struggle to meet customer demands. Investing in an AS/RS system will help you address these challenges and gain a competitive edge through supply chain efficiencies. However, it’s important to weigh the initial cost of your AS/RS investment against its scalability and integration requirements. Be sure to consult with a reputable, experienced systems integrator to ensure that your AS/RS meets your operation’s expectations and budget.
Internet of Things (IoT)
IoT is an emerging technology that can help kho lanh thuc pham facilities with monitoring, data logging and remote management. By connecting sensors to a cloud platform, this technology can monitor temperature fluctuations, send alerts and improve operational efficiency. It can also uncover new opportunities for automation that can reduce costs and improve processes.
For example, a vaccine tracking system uses IoT to remotely monitor the temperature of every location throughout the supply chain. When the temperature rises too high in a refrigeration unit, the device will automatically send an alert to the supplier. This allows them to reroute shipments and temporarily store them somewhere else, avoiding spoilage in transit. This kind of immediate response can prevent up to 40% of food from going to waste in the United States.
Additionally, IoT can be used to reduce logistics cost by optimizing energy consumption. Smart HVAC systems can turn off or activate cooling units in response to temperature changes, which can save up to $50 a year in energy expenses. Similarly, IoT tracking solutions can reduce logistics costs by improving routing practices, enabling vehicles to travel for less time and saving fuel.
In addition to improving logistics costs, IoT can improve worker safety by reducing manual labor in refrigerated environments. Robotic solutions like automated storage and retrieval systems (AS/RS) allow warehouses to use conveyors, pallet shuttles or autonomous mobile robots for warehouse operations in cold environments. This can reduce human error and speed up workflows, leading to increased productivity and reduced staff turnover.
Robotics
Cold storage facilities are complex operations with unique requirements. Automation systems streamline processes and improve operational efficiency while providing a high ROI.
Projected minimum wage increases and a workforce shortage are motivating more warehouse owners to consider investing in automation for their cold stores. At the same time, it’s more important than ever to build resiliency against future disruptions. Fortunately, automation technology is becoming more affordable and flexible.
Besides the obvious benefits like cost savings and labor reduction, automation in cold storage can boost energy efficiency in several ways. For example, automated systems reduce door movements, which prevents heat loss and ensures cold chain compliance. They also allow warehouses to optimize space with a smaller footprint and higher density, thus reducing energy usage. Innovations like inverters that recycle energy further amplify efficiency.
Another way to reduce energy consumption is through smarter storage technology that allows for more pallets in the same space. For instance, ASRS systems enable 3x the storage density compared to traditional warehouses by using robotic cranes that can stack pallets 5 racks high without compromising safety or quality. This allows food manufacturers to fit more perishables in each warehouse, preventing the need for overstocking. In addition, regenerative technologies capture waste heat and use it to power the system, further improving energy efficiency. It’s no wonder that cold storage automation is transforming the industry.