Baby, It’s Cold Inside — Cold Storage Racking Solutions

Written by Stuffey | Jan 6, 2020 7:06:43 PM

Cold storage has become a top priority for the pharmaceutical and biotech industries. The demand for temperature-controlled pharmaceuticals is soaring, with production outpacing non-temperature-controlled products at more than twice the rate.

But this growth brings some serious challenges, including:

More SKUs that need expanded storage capacity.
FIFO (First In, First Out) compliance to reduce waste and expired products.
End-to-end inventory transparency to manage logistics efficiently.

It's no surprise that cold chain logistics has become a booming industry. In 2024, the global cold chain logistics market was valued at $324.85 billion, and it's projected to skyrocket to $862.33 billion by 2032 — that's a 13% annual growth rate.

All of this highlights just how vital smart cold storage racking solutions are for keeping up with growing demands, streamlining space, and ensuring product integrity.

Running a cold storage warehouse comes with its fair share of costs:

Keeping storage temperature-controlled to protect products.
Managing different temperature needs for different items.
High energy consumption, which adds up fast in cold environments.
Labor costs, which make up a whopping 70% of total warehouse expenses.

With all these expenses, it's tempting for pharmaceutical companies to think building or leasing a new freezer storage facility is the easiest solution. But here's the thing: repurposing unused or underutilized warehouse spaces often delivers a much better return on investment.

Repurposing Pharmaceutical Storage Space

With freezer and cooler environments costing around $200 per square foot to build, it just makes sense to maximize what you already have. Constructing or outfitting a leased space often disrupts daily operations, but a customized refit of your existing space can increase capacity and make workflows more efficient.

Using high-density mobile storage and cold storage racking, pharmaceutical manufacturers and biotech companies can achieve significant savings on both energy and labor:

Energy Savings: Densely packed coolers reduce energy consumption by minimizing air escape. In fact, high-density mobile storage can lower utility costs in cold storage warehouses by up to 50%
Space Efficiency: High-density systems and cold storage racking allow you to double the number of pallet positions in the same footprint, making every square foot work harder for your business.

There are big labor benefits, too. The average warehouse order-picker walks between 7 and 13 miles per shift. With compact, mobile storage, products are easier to access and find, cutting down on travel time. Fewer unnecessary touches also help streamline operations, supporting lean warehouse practices like sorting, straightening, standardizing, and sustaining efficiency.

The Right Storage Prescription

Today's cold storage racking systems are built to handle extreme temperatures, ranging from -4°F to -20°F. Even better, these systems integrate seamlessly with your existing pallet and heavy-duty racking, making upgrades simpler and more efficient.

For one aerospace client, Patterson Pope partnered with Spacesaver to design a custom "cold package" for storing carbon fiber composites at the precise temperature needed to extend shelf life. "If you want to increase shelf life, it has to be cooled to -10°F," explained Bob Scott, process engineer for Web Industries.

The solution involved reengineering the electronics, wiring, shelves, wheels, and motors for standard ActivRAC carriages. The result? A temperature-insulated, heavy-duty system capable of handling up to 16,000 pounds. this setup allowed Web Industries to double its freezer capacity and add 660 pallet positions - all within its existing space.

Ready to explore cost-effective and space-saving cold storage racking solutions? Patterson Pope's experts are here to help you keep things cool. Contact us today to get started!

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