Cold Store Space Optimisation: Increasing Capacity, Efficiency and Sustainability with Combilift

In today’s challenging environment, companies are increasingly embracing the philosophy of “improving, not moving”: optimising space in the existing facilities rather than investing in costly and disruptive greenfield developments or site expansions. By contrast, maximising  within existing premises is a more sustainable and cost-effective alternative. 

In temperature-controlled environments, this approach delivers an additional advantage: reducing the refrigerated cubic volume and lowering long-term energy consumption and operating costs. 

Warehouse Design to Unlock Hidden Capacity  

A logical starting point is to assess current warehouse layouts and equipment. Traditional forklifts often require wide aisles and large turning circles, creating substantial areas of unproductive space. In cold stores, this unused space still needs to be refrigerated, adding unnecessary energy costs.  

With nearly three decades of experience, Irish manufacturer Combilift combines its versatile range of material handling solutions with intelligent warehouse design, helping businesses do more with less space: safely, efficiently, and profitably. 

Combilift has a team of highly experienced design and layout engineers who can provide companies with a free-of-charge warehouse design and layout service. This service demonstrates how warehouse space can be optimised based on the capabilities of Combilift's products, often delivering gains of up to 50% more storage space just by narrowing aisle widths and increasing racking height in the existing premises. 

Real-World Results in Cold Store Operations 

Food manufacturer Little & Cull, a leading supplier of premium prepared meals in the UK, faced space limitations from the outset of its operation. Co-owner Tom Little explains: 

“Space was limited from the outset as we wanted to free up as much room as possible for production, whilst also having plenty of freezer capacity.” 

After the addition of an electric cold store Aisle Master, the company increased approximately 30% extra storage space compared to its previous reach truck operation. Because the Aisle Master can work seamlessly both indoors and outdoors, the company also reduced fleet requirements by using a single truck instead of separate indoor and outdoor machines, which, in turn, improved both operational efficiency and cost-effectiveness. 

Material Handling Equipment Engineered for Cold Store Operations  

Equipment plays a central role in enhancing workflow optimisation. The Aisle Master articulated forklift is designed for high-density storage applications. Operating in aisles as narrow as 1.6 metres and capable of lift heights up to 15 metres, it enables operators to maximise both floor and vertical space. 

Additionally, its “truck-to-rack” capability also streamlines operations by allowing a single machine to handle unloading, transport, and storage, eliminating unnecessary double handling and optimising warehouse operations. 

Cold store environments also place unique demands on equipment performance. Reliability in low temperatures and during transitions between freezer and ambient zones is essential. Combilift’s cold store models are engineered to handle these challenges, preventing condensation-related issues and ensuring consistent operation. Features such as enclosed, heated cabs further enhance operator comfort, reducing fatigue and supporting productivity. 

Narrow-Aisle Handling with Pedestrian Stackers  

For operations where pedestrian equipment is more suitable, solutions like Combilift’s electric pedestrian range offer safe and efficient space-restricted operations.  

A key safety innovation within the Combilift pedestrian range is its patented multi-position tiller arm. At the touch of a button, the arm rotates left or right while the rear wheel pivots parallel to the chassis. That single movement repositions the operator from behind the truck to the side of it, out of the crush zone, with a clear and direct line of sight over both the load and the aisle. 

The operational benefits are significant, allowing operations in aisle widths from just 2.1 metres without compromising safety or manoeuvrability. As a result, operators place loads more precisely, reduce product damage, and the working environment is less hazardous. 

Proven Results Across Temperature-Controlled Logistics 

Companies working in temperature-controlled logistics have already seen the benefits of switching to Combilift’s pedestrian range.  

Jordan International Transport, based in Co. Tyrone, needed to expand its frozen and chilled seafood distribution without increasing the size of its freezer facility.  

Distribution Manager Barry McIlvanna explains:  

“The freezer system has to work just as hard to cool the relatively unproductive areas set aside for access. With standard racking and conventional forklifts such as the counterbalance and pallet trucks we were previously using, only about half of the space that could be used for storage. With the new Combilift, this has risen to 85% so our freezer circuit can operate much more efficiently and therefore more cost-effectively.”  

Sustainable Growth Without Expansion 

As energy costs and space constraints continue to challenge the cold chain industry, optimising existing warehouse capacity has become one of the most effective ways to improve profitability, sustainability, and operational resilience. 

By combining intelligent warehouse design with specialist narrow-aisle handling equipment, businesses can significantly increase storage density, reduce refrigeration costs, and enhance safety, all without expanding their facilities. 

For more information, visit Combilift.