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Home/Case studies/Freezer conversion, 42,000 sq ft
Drive-in lanes replaced selective racking inside an operating −10°F box, phased across four weekends.
Illustrations of drive-in racking in a freezer; not photographs of this facility.
A regional food distributor needed room for more frozen inventory. Its 42,000 sq ft facility was approaching capacity, and the company had already started evaluating the cost of a second refrigerated building. Before committing to an expansion, it asked whether the existing freezer could work harder.
The answer depended on more than fitting additional racks into the room. The facility had to keep operating throughout the project, with no production days lost.
More capacity. No additional building. The completed conversion added 2,400 pallet positions inside the existing 42,000 sq ft facility. The distributor did not need to proceed with the second building it had been pricing, and the project was completed with zero production days lost.
The existing selective racking gave the team direct access to individual pallets, but its aisle layout used a substantial share of the available space. As inventory grew, the distributor faced a choice: add refrigerated square footage or increase storage density within its current footprint.
The freezer could not simply be emptied and taken offline. The replacement needed to be installed in stages around daily operations.
LENOKERS developed a drive-in racking layout for products and pallet volumes suited to deeper storage lanes. Reducing the floor area devoted to access aisles created space for more pallet positions within the existing building.
The work was divided into four weekend phases. Each phase covered a defined section, allowing inventory to be moved and operations to continue in the rest of the facility.
What made this project work. The value of the redesign was not just the extra pallet count. It gave the distributor a way to respond to growth using a building it already operated. The installation schedule mattered just as much as the rack configuration.
Before expanding, compare the cost and operational impact of a new building with the capacity available in your current footprint.
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Dmytro and Lenokers went above and beyond my expectations. We were looking to liquidate a good amount of pallet racking from our warehouse and between our first contact and our warehouse being cleared of our racking, barely a week had passed! They were kind, courteous, and more than professional for the entire experience. I would not hesitate working with them again!
Lenokers did a great job for us. Professional and timely. I recommend there services.
Dmytro was great to work with
All went smoothly
Will definitely be calling again
Tim
Steel Tek
We had to move some inventory around very quickly to make room for a new customer and we ran out of rack space. I called Lenokers and they had exactly what we needed. Within 3 hours we had our racking and we're back to getting organized!
Thanks guys!
It was a pleasure working with Dmytro and his team to improve our warehouse! Timely communications and service.
Share your building dimensions and current pallet count. We can review the space and develop a layout to show what additional capacity may be possible.
Layout drawing and quote at no cost
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