Agile Cold Storage is a third-party logistics (3PL) provider providing storage and logistics solutions customized to client needs.

Focusing on safety and service, Agile partners with North American food manufacturers, processers, and growers in need of temperature-controlled warehousing services and brings proven technologies and a flexible solution-oriented mindset to assist in resolving their supply chain challenges.

To meet growing demand for the company’s services, Agile Cold Storage opened a new cold storage facility for frozen foods in Gainesville, Georgia in 2021.

The 3PL develops its cold storage facilities by first opening a conventional warehouse and then expanding with high-bay automated pallet storage and retrieval.

“Having conventional operations in place before we introduce automation ensures we provide a high level of service to our customers during startup and stabilization of the automation systems. Our customers trust us with their business and providing a high standard of service from the outset is critical,” said John Ripple, chief development officer at Agile Cold Storage.

Agile’s focus when automating is on proven technologies capable of delivering high value with manageable risk. The company seeks to balance aggressive construction timelines with seamless startups and reliable ongoing operation.

“For us, time is money during the construction phase, so every day we slip on a schedule has a direct cost,” Ripple said. “On the other hand, if you start on time and have ongoing problems, no one is going to remember the start date, they just remember the problems.”

The final goal was to establish a standard solution that could be replicated in other locations across the company’s growing network.

The Solution

Based on their internal expertise in warehouse automation, Agile defined precise requirements for the AS/RS solution and conducted a thorough vendor evaluation process.

Swisslog was selected for the project based on the proven quality of Swisslog Vectura cranes, the stability and functionality of Swisslog SynQ software, and the company’s reputation for installation and lifecycle support.

“Our goal was maximizing system reliability and uptime, reducing operational risk, while still achieving the benefits of automation,” Ripple said. “To accomplish that we needed an OEM partner with high-quality equipment, software that could meet our needs without customization, and a reputation for outstanding installation and commissioning support.”

The Swisslog solution deployed at Gainesville features six Vectura stacker cranes, ProMove automated pallet conveyors, Swisslog SynQ software, and crane and conveyor controls. The 125-foot cranes support 13 pallet levels, with five-deep storage for a capacity of 48,000 pallets. Swisslog ProMove conveyors enable fully automated induction into the -5 degrees Fahrenheit (-20.5° C) high-bay.

The solution is designed to support throughputs of 23 pallets in and 23 pallets out per aisle per hour.

Swisslog SynQ software integrates with Agile’s WMS and provides overall movement management and inventory control for the high-bay warehouse, including inbound, inventory location control and outbound.

“The stability and functionality of SynQ was one of the major reasons we chose Swisslog,” Ripple said. “We wanted a standard software deployment that would be simple to support and could be replicated in our other locations.”

The installation and commissioning of the AS/RS was completed on schedule, and Ripple described the startup as “flawless.”

With the increased density provided by the AS/RS, Agile can store nearly 3x more pallets in the same square footage as would be possible with conventional rack storage. The automation also supports higher throughput, efficiency and operating flexibility by supporting pallet storage and distribution as well as replenishment of picking operations in the conventional facility.

The software provides full visibility into inventory and controls the AS/RS and conveyors to simplify management.

Ripple also noted that “energy costs were about half of what we expected.”

“Visionary operators and investors realize that even efficient conventional operations will be a liability in the not-too distant future. By integrating automation into our cold storage warehouses, we are able to optimize facility density and efficiency, consistently meet our client’s requirements, and position our company for continued growth and success,” he said.

The solution was designed with standardized hardware and software to support reliability and simplify future deployments. Agile is replicating the solution deployed at Gainesville at its Macon, Georgia distribution center.