Edited by Eamonn Ryan
With the 2024 GCCA Cold Chain Conference in Cape Town fast approaching, Cold Link will be reviewing some of last year’s presentations to prepare us for what is to come. The following is by Sheldon Uys, general manager of SSI Schaefer, referencing a cold chain warehouse automation project in the Philippines for ORCA Cold Chain Solutions. It is Part 3 of a three-part article.
Longevity and ROI: a 15–20 year vision
ROI is a common concern in automated solutions, and this project’s Return on Investment (ROI) was estimated to be achieved within three to five years. However, what sets this apart is its longevity, with expectations that the infrastructure and technology implemented would endure for 15 to 20 years. This long-term perspective aligns with the commitment to sustainability and future-proofing the cold chain operation.
The project’s objective was to provide superior customer service, optimising costs and enhancing efficiency through automation. The key focus was on reducing human intervention in cold rooms, minimising errors caused by fatigue, and ultimately saving costs while ensuring the integrity of stored goods.
The team invested significant effort in material flow optimisation. Simulations and analyses were conducted to determine the most efficient material for constructing the facility, taking into account freezing water requirements and the overall demand and grid considerations.
The facility incorporated three different temperature zones:
- -18°C.
- 20°C and -25°C to prevent the formation of moisture and guaranteeing the freshness of the food products.
- Ambient temperatures each with zero to minimal human intervention.
This strategic temperature zoning is vital to preserve various products adequately to prevent degradation and energy loss.
The transferring area is kept at a controlled temperature of -18°C, from manual processing to a fully automated process, the pallets are transported via a 282m-long conveying system with weighted sensors and profile checks. Moving at a steady speed of 0.3m/sec, the pallets are automatically assigned to the respective zones without the use of pallet trucks and vehicles. With zero human intervention, it minimises error and prevents contamination.
Automated Storage and Retrieval System (ASRS): a technological marvel
The ORCA facility has four SSI Exyz automated storage retrieval machines that run vertically on tracks, operating simultaneously to provide seamless access to the stored pallets unhindered by the sub-zero temperatures. The ASRS operates with precision, optimising space utilisation and ensuring efficient retrieval and storage processes.
The facility leverages QR code technology for inventory management. Automated scanners read QR codes, feeding data into the system for automatic checking and verification. It is run from the interconnectivity station, a hub where fixed personnel monitor and manage the flow of goods, creating an efficient and interconnected system.
The ASRS system was designed with flexibility in mind, accommodating both new constructions and extensions to existing systems. This adaptability allows for the implementation of automated solutions in various settings, supporting buildings of different heights and enabling modular growth.
This case study reinforces why businesses need to embrace automation strategically. Schaefer’s success in the Philippines serves as a blueprint for other companies seeking to optimise their cold chain logistics. By adopting a phased approach, understanding unique business needs and fostering collaboration, organisations can pave the way for a more efficient and sustainable future in cold storage automation.