Cold storage is one of the most expensive and challenging links in the logistics chain. Every cubic foot of space is extremely valuable, and the low-temperature environment places stringent demands on equipment's material performance and structural stability. This case study details how we successfully implemented a high-density, high-stability, and cost-effective storage solution for a client's cold storage facility through an innovative modular linking design, creating an efficient portable stack system.
Our client, a U.S.-based food distribution company, needed to store a large volume of palletized goods in their cold storage facility and wanted to maximize space utilization. Their core challenges were:
While a traditional independent rack solution was feasible, it was not optimal in terms of cost and stability. Our engineering team designed an innovative system composed of "Inverted Stacking Racks" and a "Center Linking Pallet" to form a cohesive and sturdy portable stack structure.
We first designed an independent inverted stacking rack with internal dimensions of 51x49x71 inches (1300×1250×1800mm), providing a secure storage space for the client's palletized unit loads. The advantage of an inverted rack is its simple and efficient structure; it acts like a cover, placed directly over the lower-level goods, using the upper-level pallet as its support surface.
To achieve a three-pallet-wide storage bay while further enhancing stability and reducing costs, we introduced the "Center Linking Pallet" as a key design feature.
Mechanism: As shown in the diagram, two independent inverted stacking racks can be connected by a center linking pallet. The linking pallet is designed with special hooks that securely fasten onto the frames of the racks on either side.
Value Proposition:
Considering the racks would be used exclusively inside the cold storage, without experiencing drastic temperature changes or rain, we advised the client:
To Use Electrostatic Powder Coating: In this stable, low-temperature, dry environment, the more cost-effective powder coating provides sufficient corrosion protection. This avoids the need for the more expensive hot-dip galvanizing process, saving the client's budget. This demonstrates our expertise in providing the most suitable solution based on the actual application scenario.
By introducing the modular "Center Linking Pallet" design, we not only solved the client's high-density storage needs in their cold storage but also delivered superior value in cost control and structural stability that surpassed conventional solutions. This case proves that a deep understanding of the client's use case is the source of innovation, and intelligent engineering design can create tangible economic benefits for the customer.
Is your warehouse facing space or cost challenges? Contact our engineering team to explore a custom-designed, innovative solution for you.
