Americold Case Study

Americold Boosts Cold Storage Performance and Flexibility with ASRS Upgrade

Americold, a global 3PL leader in temperature-controlled logistics, needed to expand its Indianapolis, Indiana facility space to better serve regional customers. Originally built in 2011, the facility was designed for efficient pallet handling, with 21,000 pallet locations and a conveyor-fed high-density viapal ASRS.

By 2014, evolving customer requirements prompted Americold to partner again with viastore to improve picking performance, reduce labor, and manage inventory surges more effectively.

Utilizing simulation software, viastore identified a solution tailored to Americold’s evolving operations. Upgrades included layout changes, ergonomic improvements, and advanced software integrations between viadat WMS and RedPrairie. The result: significantly higher throughput, lower labor demands, and improved safety.

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Key Technologies

Conveyor-fed viapal ASRS with 6 aisles of triple-deep storage
Multi-level order picking with automatic replenishment
Double stack pallet separation to eliminate manual de-coupling
Multi-directional conveyor crossovers to reduce system congestion
Pack and hold functionality to store outbound-ready pallets
Two changeable temperature zones (from -10°F freezer to 34°F cooler)
viadat warehouse management system (WMS) integrated with RedPrairie WMS

"You need people with an in-depth knowledge of automated system capabilities and software interfaces. This includes good engineers, project managers and IT design talent who understand that you can't run an automated system the same way you run a conventional system." – David Bridger, Americold AS/RS Operations Manager

Results

With these upgrades, Americold has positioned itself for continued growth and leadership in the cold chain logistics space, proving that thoughtful automation investment can dramatically boost efficiency, safety, and customer satisfaction.

25% improvement in labor efficiency – Streamlined workflows allow for fewer manual handling steps.
43% increase in ASRS crane capacity per day – More pallets handled daily, increasing system productivity.
50% decrease in case picking – Half-pallet picks go directly to shipping, reducing handling work required for customers.
Improved safety and ergonomics – Semi-automated pallet decoupling eliminates strenuous manual tasks.
Enhanced flexibility – ASRS upgrades allow the system to be adapted to support 10–20 Americold customers.
Future-ready cold chain operations – The flexible ASRS layout, temperature control, and automation ensure Americold can efficiently respond to evolving food logistics demands.