Zone strategy
Cluster same-temperature SKUs in single zones with dedicated docks. Use insulated dock seals between zones. Multi-temp docks with air curtains work but energy-penalty is 15–25% vs discrete docks.
ASRS vs conventional
ASRS high-bay (25–35 m) triples pallet density and cuts labour cost per pallet by 55–65%. Payback typically 5–8 years at labour cost >€25/hr. Below that, conventional VNA or wide-aisle wins.
Refrigeration
CO₂ transcritical is now standard for new frozen DCs in temperate climates; below 32 °C ambient, transcritical parallel compression matches NH₃/CO₂ cascade on efficiency. Above 40 °C ambient, NH₃/CO₂ cascade still wins.
Energy strategy
Combine PV (roof or car-park canopy) with ice-bank thermal storage for peak-shaving. Heat recovery to office/dock heating covers 100% of winter heat demand. Target ≤28 kWh/pallet·yr in temperate, ≤38 in hot climates.
Preguntas frecuentes
When does ASRS actually pay back?
When labour cost exceeds €25/hr and pallet throughput exceeds 15,000/week. Below that, conventional VNA with lithium forklifts wins on capex flexibility.
How many docks per 10,000 m² of frozen DC?
Rule of thumb: 1 dock per 400–500 m² of frozen storage for retail replenishment DCs; 1 per 300 m² for QSR (higher turn). Add 30% peak overhead.
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- Industry
- logistics
- Temperature
- −25 °C bulk / +2/+8 °C chill
- Budget
- €10M – €80M
- Timeline
- 14–24 months
- Equipment
- Multi-temperature 3PL warehouse, ASRS optional, dock chillers
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