By Eamonn Ryan
As automation technologies continue to dominate discussions about the future of warehousing, it would be easy to assume that modern cold stores are rapidly becoming fully automated environments. According to Martin Bailey of Industrial Logistics Systems, however, the reality remains very different.
© Cold Link Africa
Speaking during a recent presentation in Cape Town, Bailey pointed out that despite decades of technological advancement, the overwhelming majority of warehouse activities are still performed by people.
This is particularly true in cold storage environments, where extreme temperatures, changing product profiles and operational complexity continue to challenge even the most sophisticated automation systems.
Although automated guided vehicles and robotic technologies receive significant attention, conventional power pallet trucks remain the primary method of moving goods within warehouses around the world. Their simplicity, reliability and flexibility make them difficult to replace, particularly in facilities where operational requirements change regularly.
Bailey observed that while fully automated systems undoubtedly have a role to play, their adoption within South Africa remains relatively limited. In many cases, the business case simply does not justify the investment, particularly when compared with the adaptability offered by human-operated equipment.
Conveyors represent one area where automation has achieved widespread success. Once installed, conveyor systems can operate reliably for many years with relatively modest maintenance requirements. In operations involving high volumes of case handling, they often provide significant productivity improvements while reducing manual handling requirements.
Yet when it comes to order picking, one of the most labour-intensive warehouse activities, people remain indispensable.
Bailey estimated that approximately 99% of all piece and case picking globally is still carried out manually. While robotic picking systems continue to improve, they have yet to achieve widespread adoption in the demanding environments typically found within cold chain operations.
As a result, modern cold stores continue to rely heavily on specialised order-picking equipment designed to improve worker productivity while reducing physical strain. Low-level order pickers remain common, while more advanced machines allow operators to access products at moderate heights without requiring separate lifting equipment.
The industry has also begun adopting semi-automated technologies that complement human workers rather than replace them. Bailey highlighted examples of equipment capable of following operators through aisles and automatically transporting completed loads to designated drop-off points. These systems can reduce unnecessary travel time and improve productivity without requiring the significant investment associated with full automation.
One particularly interesting development is the use of pick-to-belt systems in frozen environments. Although still relatively uncommon in South Africa, these systems have gained popularity in Europe, particularly in high-volume operations.
In a pick-to-belt environment, operators place products directly onto conveyor systems as they pick them. The products are then transported to central sorting areas where they are allocated to individual customer orders. The approach can dramatically improve picking efficiency because workers spend less time handling completed pallets and more time focusing on product selection.
However, Bailey noted that this efficiency comes at a cost. While the picking process becomes simpler, the sorting operation becomes considerably more sophisticated. Advanced conveyor and sorting technologies are often required to ensure products are correctly directed to their final destinations.
An additional advantage is that the sorting operation can often be located in a warmer environment than the freezer itself. This improves working conditions while reducing the amount of equipment that must operate continuously in sub-zero temperatures.
Despite the growing influence of technology, Bailey repeatedly returned to the importance of human factors. The success of a cold store depends not only on storage density and throughput but also on the comfort, safety and productivity of the people working inside it.
Advances in freezer clothing, ergonomic equipment design and workplace planning have all contributed to improved performance. In many cases, relatively small improvements in worker comfort can generate significant productivity gains over time.
As operators seek to balance technology investment with workforce efficiency, another issue has become increasingly important: energy.
In the next article, we explore how rising electricity costs, solar power, battery technologies and infrastructure constraints are reshaping the design of modern cold storage facilities.