Cold Storage

Built to Perform in the Cold

High-density storage systems engineered for temperature-controlled environments, from blast freezers to refrigerated distribution centers.

Pallet Flow

Pushback

Carton Flow

The Storage Challenge

Temperature-controlled warehousing is among the most demanding storage environments in North America. Space is expensive, FIFO compliance is non-negotiable, and equipment must perform reliably at temperatures as low as −40°C. Every square foot has to work harder.

Component Reliability in Extreme Cold

Rails, wheels, and carts must perform reliably at sub-zero temperatures without added maintenance or special modifications.

Maximizing Density in Costly Space

Refrigerated and freezer space costs significantly more to build and operate than ambient warehousing, making storage density a direct driver of total cost.

Minimizing Aisle Space and Forklift Travel

Reducing aisle footprint and forklift travel helps control both construction and long-term operating costs in temperature-controlled environments.

Explore the Systems

The systems most commonly specified for cold storage installations across North America.

Pallet Flow Racking

Gravity flow systems that move pallets from a load aisle to a separate unload aisle, well-suited to high-volume, single-SKU cold storage applications. Rated for use down to −40°F.

Why it fits

High-volume single-SKU storage, reduced forklift travel, proven performance in refrigerated and freezer environments.

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Pushback Racking

A high-density system rated for use down to −58°F, with no special modifications required. Configuring multiple lanes per product allows first-in-first-out rotation to be achieved through proper lane management, not automatically, but reliably when set up correctly.

Why it fits

Deepest cold-rated performance of the three systems, multi-SKU density from a single aisle, proven in large-scale freezer conversions.

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Carton Flow Racking

For refrigerated pick operations requiring case or carton level access, with multiple track configurations available for varying carton types.

Why it fits

Case-level picking, compact pick face, configurable for cold storage picking operations.

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Mars Pet Care

Pushback Racking

Cold Storage

When the building next door becomes a freezer

Mars Pet Care wanted to take advantage of global bulk pricing on meat products for their Columbus, Ohio pet food plant, but had no space within the existing facility. The solution was straightforward in concept and complex in execution: purchase the vacant building next door and convert it from ambient temperature to a freezer. Mars brought in their local material handling dealer, McCormick Equipment of Perrysburg, Ohio, who in turn brought in 3D Storage Systems to help design the layout.

The Challenge

The conversion needed to maximize storage density within 154,000 square feet while maintaining enough selectivity to rotate product on a FIFO basis.

The Solution

Mars purchased a vacant building next door and made plans to convert it from ambient temperature warehouse into a freezer. Mars asked their local material handling dealer, McCormick Equipment in Perrysburg, Ohio to assist them with a high-density storage layout and McCormick, in turn, contacted 3D Storage Systems to help out. Together 3D and McCormick came up with a plan that maximized storage while still ensuring enough selectivity to rotate product on a first-in-first-out basis. The new facility has just over 18,000 pallet positions of 2, 3 and 4 deep pushback situated in 154,000 square feet of a unique freezer within a building. The project was very cost-effective because it utilized pushback over double stacked floor storage, ensuring high density without having to pay for carts, rails, and beams on the bottom level.

18,000+

Pallet positions

Pick faces vs. drive-in rack

154,000 sq ft

Freezer facility size