Cold Storage Expansion at Ontario Produce Hub
Engineering Case Study
Case Study 2: Cold Storage Expansion at Ontario Produce Hub
Scenario
A temperature-controlled produce distribution hub in Brampton, ON expanded its -25°C frozen storage wing to accommodate seasonal berry volume spikes. The new zone featured drive-in racking with 4.2 m beam elevation and tight thermal envelope constraints limiting aisle width to 3.4 m. Critical constraints included: (1) forklift hydraulics performance degradation below -20°C requiring minimal mast cycling, (2) ice accumulation on floor reducing traction, and (3) compliance with CSA B335-18 and ANSI/ITSDF B56.1 safety margins for cold environments.
Given Data
- Rack beam elevation: 4.2 m
- Forklift lowered mast height: 2.65 m
- Clearance: 0.35 m
- Aisle width: 3.4 m
- Forklift width: 1.25 m
- Pallet width: 1.18 m
- Safety margin: 0.22 m
Calculation
Free Lift = Rack beam elevation − Forklift lowered mast height − Clearance
= 4.2 m − 2.65 m − 0.35 m = 1.20 m
Extended Reach = (Aisle width − Forklift width) / 2 − Pallet width − Safety margin
= (3.4 m − 1.25 m) / 2 − 1.18 m − 0.22 m
= (2.15 m / 2) − 1.18 m − 0.22 m
= 1.075 m − 1.18 m − 0.22 m = −0.325 m → Infeasible
However, drive-in racking permits side-entry — so extended reach is reinterpreted as minimum fork extension needed to clear uprights. Using standard upright thickness (0.12 m) and required fork overhang (0.15 m): Effective extended reach needed = Upright thickness + Fork overhang = 0.12 + 0.15 = 0.27 m
Given aisle width allows forklift to position offset from centerline, actual usable reach = (Aisle width − Forklift width − Upright thickness) / 2 = (3.4 − 1.25 − 0.12)/2 = 2.03/2 = 1.015 m, well above 0.27 m.
Thus, extended reach constraint is satisfied operationally, though the base formula assumed selective racking geometry.
Result and Decision
A cold-rated order picker with 1.35 m free lift (exceeding 1.20 m requirement) and 1.1 m maximum horizontal fork extension was selected. Its low center of gravity and sealed hydraulic system maintained responsiveness at -25°C. The solution avoided costly aisle widening (estimated $185k) and met CSA B335-18 stability thresholds at 100% rated capacity.
Lesson
Tool formulas assume standard selective racking assumptions; drive-in, push-back, or pallet-flow configurations require context-aware reinterpretation of 'extended reach'. Always map the tool’s output to actual operational kinematics—not just arithmetic feasibility.