Case Study: United States Cold Storage achieves 85 pallets/hour seamless deep-freeze production-to-distribution automation with Swisslog Holding

United States Cold Storage - Customer Case Study

United States Cold Storage (USCS), a long-established leader in refrigerated logistics operating 36 facilities and nearly a million pallet positions, needed a way to connect an expanded ice cream production line to a new, plant‑attached distribution center in Covington while operating in a -20°F deep‑freeze environment. USCS’s challenges were to move pallets safely across a roadway, hold product for 24 hours, minimize manual operator travel and exposure, and maintain high throughput — problems Swisslog Holding addressed using automated material‑handling technologies (AGVs, ProMove conveyors, Vectura cranes, ASRS) and WM6 warehouse management software.

Swisslog Holding engineered and implemented an end‑to‑end automation solution: AGVs pick pallets from production, a 25‑ft elevated corridor with ProMove conveyors conveys product to a “butterfly” ASRS serviced by two Vectura cranes (about 4,000 temporary pallet positions), and WM6 integrates tracking and controls. The system delivers measurable results — seamless production‑to‑distribution flow at 85 pallets/hour, reduced manual travel and exposure for operators, full weekend automated holding, improved traceability, and recognition with a Design‑Build Institute Award after commissioning in 2015.

United States Cold Storage