Industrial cold storage is a foundational requirement for major export sectors, particularly across dairy, produce, and meat processing. Maintaining a precise cold chain is essential for product integrity, yet the physical demands of sub-zero environments often hinder manual operational efficiency and equipment longevity.
To address these specific hurdles, we provide advanced ASRS cold storage technology engineered to perform where standard machinery fails, ensuring that high-volume throughput is maintained without compromising safety in New Zealand facilities.
The Realities of Low-Temperature Storage
Operating a facility at -20°C or below introduces significant mechanical and structural stressors that can compromise both safety and total facility output.
Mechanical Integrity
In extreme cold, standard batteries experience rapid capacity loss and shortened runtimes, leading to frequent charging cycles. Structural materials, including certain steels and plastics, are prone to becoming brittle and failing under stress, while electronic sensors may drift or malfunction due to the harsh thermal environment.
Ice and Moisture Management
The entry of ambient air during door cycles creates condensation that quickly turns to ice on moving parts. Ice build-up on guide rails often leads to pallet misalignment, disrupting the movement of shuttles and reducing the traction required for accurate positioning and rapid acceleration.
Servicing Hurdles
Maintenance in freezer environments carries higher safety risks for technicians and requires specialised protective gear. Because personnel require frequent breaks from the cold, service events often result in longer cumulative downtime and increased operational expenditure compared to ambient warehouse environments.
Dexion’s MDS ASRS 4-Way Shuttle for Cold Storage Warehouses
The MDS ASRS four-way shuttle represents a significant technological leap, evolved directly from the HDS Shuttle—a high-density 2-way system with a long-standing track record in cold environments. This system is built upon 15 years of technical experience, with over 200 MDS units currently deployed in freezer environments throughout the Asia Pacific region, demonstrating proven reliability in the field.
Designed for reliable performance at a consistent -20°C, this ASRS shuttle system is versatile enough to manage diverse inventories, from seafood and meat to fresh produce and wine. The platform is fully automated for 24/7 operation, utilising AI and machine learning to optimise storage density and retrieval paths.
It remains highly flexible, offering zero-code shuttle scaling to meet seasonal demand and seamless integration with existing Warehouse Management Systems (WMS). Furthermore, our cold storage warehouse solutions are supported by an established regional network for parts, maintenance, and expert service to ensure your facility never stops.
How the MDS ASRS 4-Way Shuttle Thrives in Freezer Environments
Successfully implementing cold storage warehouse technology requires a design that actively counters the effects of thermal cycling and moisture through specialised engineering.
Equipment Durability
We employ cold-rated components and materials specifically chosen for sub-zero stability and impact resistance. Control systems are housed within enclosed, insulated designs to ensure electronic reliability despite temperature fluctuations, while remote predictive maintenance support helps identify potential issues before they cause a stoppage.
Traction and Rail Stability
The four-way shuttle system utilises a specialised wheel and rail interface tested for low-temperature and low-friction scenarios. This ensures the shuttle maintains stable traction even when faced with frost or thermal cycling, avoiding the common pitfalls of using untested contact surfaces that lead to slippage and positioning errors.
Precise Sensing
Our sensors are engineered to maintain accuracy despite sharp temperature differentials that typically cause electronic drift. They are designed to remain resistant to moisture ingress and perform reliably during the “fog” events common when freezer doors are cycled, ensuring the system remains aware of its environment at all times.
Energy and Battery Efficiency
To lower total operational costs, the shuttle is designed to power off automatically during idle periods. We utilise IP65-rated batteries built for freezer demands, which are programmed for opportunistic charging to maximise energy efficiency and ensure the fleet is always ready for peak retrieval periods.
Conclusion
Whether you are managing primary production logistics in regional areas or distribution hubs in major centres, transitioning to high-density automation ensures your cold chain remains resilient and cost-effective. Contact us to discuss how we can assist in designing or upgrading your facility with the MDS ASRS 4-Way Shuttle.
