Process automation in intralogistics is a proven tool for reducing sources of error and increasing the reliability, performance and competitiveness of processes. Especially in frozen food logistics, it is an important factor in counteracting the shortage of skilled workers and labour while at the same time reducing personnel costs, reducing the workload for employees and supporting staff retention. Against this background, the Dutch system integrator Inther Group has launched a no-hands concept with high, resource-efficient performance for the deep-freeze segment. "Manually operated deep-freeze warehouses today require unnecessary personnel, space and energy," explains Stefan Weisshap, CEO of Inther Group Germany. "Employees can only work in deep-freeze conditions for a short time. Forklifts that load and unload pallets from racks need space to maneuver. And the revolving doors or roller doors used for efficient forklift operation generate cooling losses, resulting in high energy costs."

22 percent energy savings and higher product quality
A special installation setup from the Inther Group offers a sustainable innovation that enables energy savings of up to 22 percent and provides additional storage and transport capacities. To save energy, individual boxes are fed into the freezing process instead of entire pallets. "Freezing individual boxes takes less time and energy than freezing palletized boxes down to the middle of a pallet," explains the Managing Director of Inther Group Germany. “Compared to conventional process sequences, this can save up to 22 percent energy.” The system integrator has designed a process sequence for this purpose in which the individual boxes with the finished packaging products are automatically transported directly from production to a tunnel freezer via a conveyor system at a temperature of approximately 3° Celsius. After the boxes have been quickly frozen, they are transported via a short, direct bypass and via air curtains or air locks to the buffer warehouse. The boxes remain there until they are collected for palletizing.

Efficient use of resources and improved CO₂ balance
Since the goods are frozen immediately after production, without any downtime or waiting times, the product quality is higher and the shelf life is longer than with conventional processes. At the same time, direct processing ensures less moisture and weight loss. In contrast to pallet freezing, the boxes remain dimensionally stable when they are frozen individually. Boxes that are initially placed on pallets are pressed against each other and become convex before they freeze. The frozen pallets then have a larger volume. “In total, up to eight percent more storage capacity in a 20-foot container (TEU) can ultimately be achieved by loading individually frozen and later palletized boxes,” Weisshap summarizes. “This also reduces shipping costs accordingly.” Since all processes take place directly at the production site, without long detours or external transport, Inther's solutions also contribute to reducing the CO₂ footprint and developing sustainable intralogistics. "Freezing and storing at the same location not only preserves moisture content, weight and meat quality," Weisshap summarizes. "It is even essential for exports to some markets outside Europe, such as China. With Inther's modern, automated deep-freeze solutions, these requirements can be optimally met. They also reduce energy, shipping and personnel costs, reduce sources of error, provide greater safety and improve the CO₂ footprint. These advantages should not go unused."

Fully automated processes from production to shipping
For example, Inther Group implemented a compact storage and order picking system for frozen products with 10,000 storage locations for the Finnish meat producer Snellman. The system not only serves as storage for containers, but also as a buffer for outgoing containers from customers. In addition to pallet and flow racks, miniloads with 12 order pickers, container (de)stackers and (de)palletizers, 1,500 meters of conveyor technology at three different height levels and a sorter for retrieval, various order picking systems and peripheral equipment ensure efficient intralogistics processes. The implementation of the installation at the meat processing plant of Westfort Meat Products in IJsselstein, the Netherlands, is similar. There, Inther installed an integrated freezer storage on an area of ​​approximately 38,000 square meters. An Inther AS/RS shuttle system with 72 levels was installed for the storage of individual freezer boxes. The system automatically sorts all products in a freezing environment of -18° Celsius. With the no-hands concept that Inther has developed for deep-freeze projects, all processes of internal transport, freezing, sorting, palletising and deep-freeze storage are fully automated and no manual intervention is required, from the moment the goods are packed in production to loading in the outgoing goods zone.