Automated Cold Storage
Automated ASRS Frozen Distribution Centre — Rotterdam
European 3PL flagship: fully automated 42,000-pallet frozen DC serving Benelux retail and export markets.
Location
Rotterdam, Netherlands
Capacity
42,000 pallet positions · 38 m high-bay
Temperature
−25 °C frozen, +2/+6 °C chilled dock
Budget
USD $65M–$85M
Timeline
22 months
Project overview
A pan-European 3PL selected ColdMatch Group to structure the tender for its flagship Rotterdam frozen DC. The scope combined a 38 m high-bay ASRS, CO₂ transcritical refrigeration, ammonia backup and a chilled cross-dock with 42 loading bays.
Challenge
- Land constrained: vertical density required 38 m clear-height ASRS.
- F-Gas regulation ruled out HFC refrigerants.
- Retail SLA required 99.7% order accuracy and 4-hour cut-off.
Solution
- Head-to-head tender across 4 ASRS OEMs, 3 rack suppliers and 2 refrigeration integrators.
- CO₂ transcritical plant with heat recovery to adjacent office block.
- Independent commissioning agent embedded from month 6.
Result
- CAPEX bid tension delivered 11.4% saving vs. sole-source baseline.
- PUE-equivalent energy 28% below industry benchmark.
- Live within timeline; retail SLA reached in month 3 of ramp.
Scope of works
- 38 m ASRS with pallet shuttles and cranes
- CO₂ transcritical refrigeration + ammonia backup
- Chilled cross-dock with 42 loading bays
- WMS/WCS integration and BMS
- Fire protection (ESFR + inert gas for ASRS)
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