Imagine running a thriving cold storage warehouse business with orders pouring in like snowflakes, yet finding your facility magically resistant to expansion. This was the predicament facing Zero Mountain, a frozen food distributor based in Fort Smith, Arkansas. With growing inventory demands but limited geographical options for traditional expansion, the company needed an innovative solution to increase capacity within its existing footprint.
Turning Constraints Into Opportunities
Rather than accepting physical limitations, Zero Mountain partnered with automation integrator Cisco-Eagle and rack manufacturer Steel King Industries to develop a space optimization strategy. Their collaborative approach focused on reconfiguring internal layouts and upgrading storage systems to maximize every square foot.
The "Every Inch Counts" Storage Solution
Conventional expansion through additional construction wasn't feasible. Instead, the team identified underutilized spaces throughout the facility, including a small room in the unloading area that had previously gone unnoticed. To transform this modest space into productive storage, they implemented pushback racking —a high-density system allowing two pallets to occupy each storage position along the room's perimeter.
Consolidating Storage Through Smart Design
The transformation extended beyond niche spaces. Zero Mountain replaced traditional selective racking with drive-in racking systems that eliminate multiple aisles to increase storage density. While this configuration reduces some accessibility, it proved ideal for their high-volume, low-SKU frozen product inventory.
By strategically reducing aisle space and consolidating storage units, the drive-in racks created significant capacity gains. This approach demonstrates how thoughtful system selection can dramatically improve space utilization without expanding physical facilities.
A Model for Cold Storage Optimization
The successful collaboration between Zero Mountain, Cisco-Eagle, and Steel King Industries yielded a 600-pallet capacity increase within the same footprint. Their achievement offers valuable lessons for cold storage operators facing similar constraints:
1. Reclaim marginal spaces: Undervalued corners, small rooms, and narrow passages can become productive storage areas with customized solutions.
2. Match systems to needs: High-density options like pushback or drive-in racking work best for specific product types, while automated storage and retrieval systems may suit other operations.
3. Prioritize partnerships: Successful warehouse optimization requires close collaboration between operators, integrators, and equipment specialists to develop tailored solutions.
Zero Mountain's experience proves that physical limitations needn't constrain growth. Through innovative thinking and strategic system upgrades, cold storage facilities can achieve remarkable capacity improvements without expanding their footprint.