Frozen food logistics and high-bay freezer warehouses: Modern pallet storage technologies for optimal cold chains

Infrastructure for freshness: The potential of high-bay deep-freeze warehouses

Frozen food logistics is playing an increasingly important role in the modern food industry. With an annual consumption of almost 47 kilograms of frozen food per capita in Germany and a rising trend, the market is growing continuously. This report examines current developments, challenges, and technological innovations in frozen food logistics, with a particular focus on high-bay freezer warehouses as key infrastructure elements of this specialized sector. The specific requirements for temperature control, constant monitoring, and an unbroken cold chain present companies with complex logistical challenges that can be addressed through modern automation and control technologies.

Suitable for:

• Cold Chain Logistics Strategies: For more sustainable refrigerated and frozen food logistics in global industrial logistics

Fundamentals of frozen food logistics

Frozen food logistics deals with the transport, storage, and handling of goods at constant temperatures between -25 and -18 degrees Celsius. This specialized form of logistics is essential for the food industry, particularly for manufacturers and distributors of frozen products such as ice cream, baked goods, meat, vegetables, ready meals, and potato products. An unbroken cold chain under controlled transport conditions is the fundamental requirement for maintaining the quality of all frozen products.

The demand for frozen products has risen significantly in recent years, leading to an increased need for specialized storage infrastructure. This trend is further amplified by the growth of online grocery shopping with its wide selection and convenient delivery services. The challenge for logistics providers is to meet this rising demand while simultaneously complying with stringent temperature and quality requirements.

Frozen food logistics encompasses various elements: from production and storage to transport and delivery to the end customer. Each step in this chain requires specialized facilities and technologies to maintain the necessary temperatures. Key components of this infrastructure include high-bay freezer warehouses, refrigerated transport vehicles, and handling facilities, all designed to meet the specific requirements of the frozen food sector.

Market developments and current challenges

The market for frozen foods is growing steadily, with variety and availability showing a clear upward trend in recent years. This development presents the industry with several key challenges.

One of the biggest challenges in frozen food logistics is the persistent labor shortage. The extreme working conditions at temperatures of -18°C and below make it difficult to find and retain qualified personnel. The physical strain and the need to wear warm protective clothing contribute to low employee motivation. This situation is exacerbated by rising labor costs, which negatively impacts company profitability and increases the pressure to automate operations.

Another critical factor is high energy consumption. Cold storage facilities require immense amounts of energy to maintain the necessary low temperatures. This leads to high energy costs, which represent a significant portion of operating expenses. Companies are therefore faced with the challenge of implementing energy-efficient technologies and equipment to reduce both costs and environmental impact.

The rising demand has also led to an increased need for storage space. Since acquiring new land is expensive, companies must make optimal use of their existing storage capacities. This explains the trend towards high-density storage solutions such as high-bay warehouses and automated systems, which can use available space more efficiently and maximize storage capacity.

Deep-freeze high-bay warehouses as a modern solution

High-bay freezer warehouses represent the most modern solution for the challenges of frozen food logistics. These specialized facilities are designed to store large quantities of frozen products at constant temperatures while making optimal use of available space.

Construction methods and dimensions of modern high-bay deep-freeze warehouses

Modern deep-freeze high-bay warehouses are typically constructed as silo-style channel storage systems with shuttle vehicles or stacker cranes. This self-supporting design allows for maximum use of available space and offers impressive capacities. The dimensions of these systems are often considerable

The Cool Port 2 deep-freeze high-bay warehouse in Rotterdam, operated by Lineage Logistics/Kloosterboer, measures 69 meters in length, 139 meters in width, and 41 meters in height, offering space for 60,000 pallet positions. 4,100 tons of steel were used in the construction of this self-supporting silo structure.

Another example is the high-bay deep-freeze warehouse of the Coppenrath & Wiese confectionery company, which is approximately 85 meters long, 34 meters wide, and 33 meters high, and has over 20,000 pallet spaces. The deep-freeze logistics center in Wustermark (TCW) is similarly sized, providing storage capacity for more than 20,500 pallets.

The Belgian company Coldo is currently building a high-bay deep-freeze warehouse which, upon completion at the end of 2025, will offer almost 60,000 pallet spaces and achieve a throughput of 400 pallet movements per hour.

Key performance indicators and efficiency

The performance of modern high-bay freezer warehouses is impressive. They are designed for high throughput rates to meet the demands of the fast-paced food industry. For example, the Coppenrath & Wiese high-bay freezer warehouse achieves a throughput of 200 double cycles per hour, while the Coldo project is designed for 400 pallet movements per hour.

Another important aspect is the efficiency of loading and unloading. At Cool Port 2, four trucks can be unloaded per hour, which corresponds to an hourly incoming goods volume of 136 pallets. This high performance is crucial for the smooth handling of logistics processes.

Energy efficiency is another advantage of modern high-bay freezer warehouses. Thanks to their compact design and optimized space utilization, the volume to be cooled can be reduced, leading to significant energy savings. The Cool Port 2 high-bay freezer warehouse, for example, is 35-45% more energy-efficient than a conventional freezer warehouse.

Automation technologies in frozen food logistics

The extreme conditions in deep-freeze facilities and the shortage of skilled workers have led to a high degree of automation in frozen food logistics. Automated processes are worthwhile in all areas of logistics, but especially at extremely low temperatures.

Suitable for:

• German industry is experiencing a veritable high-rise frenzy: High-bay warehouses are transforming logistics sustainably and digitally

Shuttle systems and storage and retrieval machines

One of the most important automation technologies in deep-freeze high-bay warehouses are pallet shuttle systems. These systems enable multi-deep storage and thus maximize space utilization. The MULTIFLEX pallet shuttle system from DAMBACH, which is used at Coppenrath & Wiese, works on the following principle: The carrier transports the shuttle "piggyback" to the desired channel, which then autonomously enters the channel, picks up or drops off a pallet, and returns to the carrier.

A similar system is the PowerStore system from Swisslog, which is used at Virto in Spain at an ambient temperature of minus 30 degrees Celsius. Designed as a compact storage system with multi-deep aisles, the shuttle system ensures high space utilization and is particularly suitable for facilities with structural limitations where very high storage density combined with maximum throughput is crucial.

Storage and retrieval machines (SRMs) are another important technology. In Cool Port 2's high-performance deep-freeze warehouse, six SRMs handle the storage and retrieval of hundreds of heavily loaded pallets per hour at temperatures as low as -25°C. A special feature is the Satellit® load handling device, which engages profiles that support and protect the pallets. This design increases the pallets' lifespan and prevents damaged pallets from jamming and blocking the system.

Adjustments for deep-freeze conditions

The extreme temperatures in deep-freeze warehouses place special demands on the technology used. Therefore, individual components must be specially adapted to ensure that the systems function reliably even at these temperatures. These adaptations range from the specific design of timing belts to the use of cold-resistant lubricants and similar components.

The basic technological framework remains the same, but certain components need to be adapted to ensure the technologies are and remain suitable for deep freezing. The cooling phase is a crucial process, as it reveals whether, for example, containers deform or similar problems occur.

Software and control systems

Automation in frozen food logistics is supported by advanced software solutions. Warehouse Management Systems (WMS) now monitor goods and the vehicles that transport them. Inventory is tracked using portable RF scanners and even drones. Computers handle warehouse loading planning, product placement, and employee task management.

An example of an advanced control system is the Savanna.NET® Warehouse Execution System (WES) from Westfalia, which manages the complete warehouse operations and material flow control at Cool Port 2. As an all-in-one software solution, it combines comprehensive functions of warehouse management software and warehouse control software. It also offers a customized interface for customers and maximum transparency of logistics performance.

Efficiency and sustainability in frozen food logistics

Frozen food logistics faces the challenge of managing high operating costs due to energy consumption while simultaneously implementing sustainable solutions.

Energy efficiency as a key factor

Deep-freeze warehouses consume immense amounts of energy to maintain the required low temperatures. Modern high-bay deep-freeze warehouses therefore rely on energy-efficient technologies and construction methods to reduce energy consumption.

One example is the compact design of shuttle warehouses, which reduces the volume of space requiring cooling and thus results in significant energy savings. Furthermore, these systems are characterized by a good power-to-weight ratio: while large storage and retrieval machines weigh several tons, a carrier with a shuttle weighing approximately 1,000 kg moves a load of 1,000 kg.

The Cool Port 2 high-bay deep-freeze warehouse in Rotterdam is 35-45% more energy-efficient than a conventional deep-freeze warehouse thanks to these and other measures. It was built according to BREEAM requirements and is designed to support up to 2,700 solar panels for on-site energy generation if needed.

Sustainable concepts and solutions

Sustainability is becoming increasingly important in frozen food logistics. Although climate change and sustainability issues have temporarily faded into the background of public discourse, this does not change the fact that sustainable business practices are a prerequisite for a future-proof economic world.

Many current trends in logistics also contribute to sustainability through increased efficiency. Ultimately, everyone benefits: the environment, people, and companies. Examples of sustainable concepts in frozen food logistics include energy-efficient refrigeration units, optimized storage density, and the use of renewable energies.

Automation also contributes to sustainability by optimizing processes and using resources more efficiently. Automating processes such as warehouse management and route optimization minimizes errors and reduces costs associated with manual labor, fuel, and storage.

Practical examples of state-of-the-art high-bay deep-freeze warehouses

The theoretical concepts of frozen food logistics are finding practical application in various impressive projects worldwide. These case studies demonstrate the diversity and innovative strength of the industry.

Cool Port 2 Rotterdam: A prime example of modern frozen food logistics

The Cool Port 2 deep-freeze high-bay warehouse at Rotterdam City Terminal, operated by Lineage Logistics/Kloosterboer, commenced operations in January 2022. It initially serves its anchor customer, Lamb Weston/Meijer, one of the largest producers of frozen potato products. Export products from the Dutch production sites are handled via the Port of Rotterdam, delivered to Cool Port 2, loaded onto containers, and transported by inland waterway vessel to the container terminals at Maasvlakte.

The 6-aisle, fully automated, high-bay deep-freeze warehouse is 69 meters long, 139 meters wide, 41 meters high, and comprises 60,000 pallet positions. It operates at temperatures as low as -25 °C and is equipped with six stacker cranes that reach a height of approximately 38 meters.

A key feature of Cool Port 2 is its high-performance sequencing buffer, which supports its immense throughput. The storage and retrieval machines retrieve goods unsorted and efficiently along their routes; only in the buffers is the merchandise sequenced according to container requirements. This combination of compact storage, high capacity, and enormous loading speed makes Cool Port 2 a flagship project for the industry.

Deep-freeze high-bay warehouse at Conditorei Coppenrath & Wiese

The confectionery company Coppenrath & Wiese (CCW) has built a deep-freeze high-bay warehouse in its logistics center, internally designated as “Deep-freeze high-bay warehouse 6 (TK-HRL 6)”. With a length of approximately 85 meters, a width of 34 meters and a height of 33 meters, it offers space for 20,000 pallet positions.

What makes this project special is the use of the MULTIFLEX pallet shuttle system from DAMBACH. It enables a higher storage capacity than the previously used systems with stacker cranes and individual access. The system, which is temperature-controlled at -25°C and oxygen-reduced, has 12 levels and can accommodate both Euro pallets and industrial pallets.

The symmetrically designed system enables a very high pallet throughput of 200 double cycles per hour. At least six conventional storage and retrieval machines would have been required to achieve this performance.

Further projects and application examples

The Belgian company Coldo, a provider of frozen food logistics and a specialist in third-party logistics (3PL), is currently building a state-of-the-art high-bay deep-freeze warehouse, scheduled to go into operation at the end of 2025. Equipped with 32 "Movu atlas" pallet shuttles, it will offer almost 60,000 pallet spaces and achieve 400 pallet movements per hour. Coldo will store a wide variety of frozen products in the warehouse, including meat, ice cream, bread, vegetables, French fries, and potatoes.

Another example is the planned deep-freeze warehouse of Wiesbauer Gourmet Gastro, scheduled to go into operation in autumn 2026. This project focuses on automation to make work processes more efficient and relieve staff of physically demanding tasks. A planned automated small parts warehouse will operate at approximately -22 degrees Celsius and will use trays as loading aids. With a capacity of over 21,000 storage locations, it will offer ample space for flexible warehousing.

Trends and future prospects

Frozen food logistics is constantly evolving, driven by technological innovations and changing market demands.

Digitalization and automation

One of the most remarkable trends in logistics today is the digitalization of all processes. Automating processes such as warehouse management and route optimization minimizes errors and reduces costs associated with manual labor, fuel, and storage. In 2025, the logistics and supply chain industry will continue to be heavily influenced by new technologies such as AI, automation, and robotics.

The intralogistics industry is preparing for further innovations. Intralogistics specialist SSI Schäfer has announced a “revolutionary automation solution” for LogiMAT 2025, which is expected to be a game changer for the industry. Exhibition highlights will include robotics applications, shuttle and overhead conveyor technology, and solutions for frozen food logistics.

Artificial intelligence and machine learning

Artificial intelligence (AI) and machine learning are increasingly being integrated into daily operations to optimize processes and increase efficiency. In the logistics industry, AI is no longer a separate trend, but an indispensable component of almost all logistics trends.

A key aspect for 2025 is the increasing predictive capability of IT systems, which improves planning and scalability. With increasing digitalization, the vulnerability of companies also rises, making cybersecurity more important than ever – especially for a critical sector like logistics.

Robotics in frozen food logistics

The use of robots in logistics is steadily increasing, particularly in markets with high labor costs and rising expectations for fast deliveries. Thanks to robots, warehouse processes are automated and navigated autonomously. They support inventory management through real-time information and enable precise delivery time forecasts.

Robotic solutions include picking robots, sorting robots, packing robots, autonomous vehicles, and drones. These technologies are particularly interesting for frozen food logistics, as they can reduce the need for human labor under extreme temperature conditions.

Suitable for:

• Daifuku Europa: Automation of intralogistics through Autonomous Mobile Robots (AMR) and Automated Guided Vehicles (AGVs)

Frozen food logistics in transition

Frozen food logistics faces numerous challenges, but also offers diverse opportunities for innovation and optimization. The growing market for frozen products, the shortage of skilled workers, high energy costs, and increasing sustainability requirements are driving the development of new technologies and concepts.

High-bay freezer warehouses play a central role as an efficient and sustainable solution for storing large quantities of frozen products. With their impressive dimensions, high performance, and innovative technologies, they set new standards in the industry. Automated systems such as shuttle solutions and stacker cranes optimize space utilization and throughput, while advanced software solutions ensure transparency and efficiency.

The future of frozen food logistics will be shaped by digitalization, AI, and robotics. These technologies will help to further optimize processes, improve energy efficiency, and facilitate working conditions. At the same time, sustainability aspects will gain importance in order to reduce the environmental footprint of energy-intensive frozen food logistics.

For companies in the frozen food logistics sector, this means they must continuously invest in new technologies and concepts to remain competitive and meet changing market demands. Successful examples such as Cool Port 2 in Rotterdam or the high-bay frozen food warehouse of the Coppenrath & Wiese confectionery demonstrate that such investments pay off through increased efficiency, lower operating costs, and improved customer satisfaction.

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Konrad Wolfenstein

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