High-Density Frozen Storage Facility for Lynca Meats
Mobile Pallet Racking (MovoRack) Optimises Freezer Capacity for a Growing Meat Processing Operation
As demand for frozen meat storage increased, Lynca Meats, one of South Africa’s established pork producers and distributors, required a modern cold storage facility capable of supporting higher product volumes while maintaining strict temperature control.
To meet these requirements, Lynca partnered with Logistics Systems Engineering (LSE) to design and install a high-density storage solution incorporating LSE’s mobile pallet racking (MovovRack) technology.
The result is a highly efficient frozen storage facility that maximises available warehouse space while maintaining full pallet accessibility, reliable temperature control, and operational efficiency
About Lynca Meats
Lynca Meats is a South African meat processing and distribution company specialising in pork products supplied to retailers, wholesalers, and food service providers.
Operating within the highly competitive meat industry requires efficient storage infrastructure capable of supporting both production throughput and distribution logistics.
To support its growth and improve inventory handling, Lynca required a new cold storage facility capable of storing large quantities of frozen products while maintaining strict freezer conditions.
The Challenge: Increasing Storage Capacity within a Limited Footprint
Lynca required a storage solution capable of handling increasing product volumes while maintaining reliable freezer operations.
The new facility needed to:
- Store large volumes of frozen meat products
- Maintain consistent temperatures of approximately −25 °C
- Maximise pallet capacity within the available warehouse footprint
- Provide direct access to every pallet
- Improve inventory control and product handling efficiency
- Support future expansion as operational demand increased
Traditional pallet racking systems would require multiple fixed aisles, significantly reducing available storage space. A more advanced storage solution was required to optimise cubic storage volume.
The Solution: MovoRack Mobile Pallet Racking System
To address these challenges, LSE designed and installed our MovoRack mobile pallet racking system within the new cold storage facility.
Mobile pallet racking systems operate on motorised bases that move laterally along rails embedded in the warehouse floor. This allows racks to move and open only the aisle required for forklift access.
By eliminating multiple fixed aisles, the system significantly increases storage density while maintaining direct access to every pallet position.
In addition to mobile racking, conventional pallet racking was also installed to support operational flexibility within the facility.
Technical Data: Lynca Meats Cold Storage Facility
Mobile Pallet Racking (MovoRack)
| Feature | Specification |
|---|---|
| Client | Lynca Meats |
| Industry | Meat Processing & Cold Storage |
| Location | Meyerton, South Africa |
| System Installed | MovoRack Mobile Pallet Racking System |
| Warehouse Size | ± 2 000m² |
| Total Pallet Capacity | ± 6 000 Pallets |
| Maximum Pallet Weight | 1 200 kg + |
| Operating Temperature | Approximately −25°C |
| Mobile Blocks | 2 Blocks + 3 Block Rails |
| Mobile Bases | 10 Bases (Block 1) / 7 Bases (Block 2) |
| Additional Racking | Back-to-Back Conventional Pallet Racking |
| Rack Height | ± 12m |
| Rack Length | ± 30m |
| Load Levels | 6 Levels |
| Future Expansion | Space for ± 2 500 Additional Pallet Positions |
Technical Data: Lynca Meats Cold Storage Facility
Mobile Pallet Racking (MovoRack)
| Feature | Specification |
|---|---|
| Client | Lynca Meats |
| Industry | Meat Processing & Cold Storage |
| Location | Meyerton, South Africa |
| System Installed | MovoRack Mobile Pallet Racking System |
| Warehouse Size | ± 2 000m² |
| Total Pallet Capacity | ± 6 000 Pallets |
| Maximum Pallet Weight | 1 200 kg + |
| Operating Temperature | Approximately −25°C |
| Mobile Blocks | 2 Blocks + 3 Block Rails |
| Mobile Bases | 10 Bases (Block 1) / 7 Bases (Block 2) |
| Additional Racking | Back-to-Back Conventional Pallet Racking |
| Rack Height | ± 12m |
| Rack Length | ± 30m |
| Load Levels | 6 Levels |
| Future Expansion | Space for ± 2 500 Additional Pallet Positions |
Engineering and Operational Efficiency
LSE’s mobile pallet racking system (MovoRacl) installed at Lynca Meats was designed to optimise storage capacity while maintaining efficient warehouse operations.
By reducing the number of aisles required for forklift access, the system significantly increases storage density within the facility.
This design also improves energy efficiency within the freezer environment, as the refrigeration system needs to cool a smaller air volume.
The system supports efficient forklift operation while ensuring that all pallets remain individually accessible, an essential requirement for meat storage and stock rotation.
Cold Storage Facility Capabilities
The cold storage facility supports Lynca’s production and distribution operations by providing high-capacity frozen storage for pork products.
Key operational capabilities include:
- Storage of more than 5,500 pallets of frozen product
- Freezer operation at temperatures as low as −30 °C
- Blast freezing capability from ambient temperature to −18 °C within 24 hours
- Efficient stock handling and product rotation
These capabilities allow Lynca Meats to maintain high levels of product quality while supporting efficient distribution to customers across the region.
Project Execution
The project involved the design and implementation of a fully integrated storage solution, including:
- Warehouse layout design and storage optimisation
- Mobile pallet racking system installation
- Conventional pallet racking installation
- Integration with materials handling equipment
- System commissioning and operational support
Through careful engineering and planning, LSE delivered a storage facility tailored specifically to the operational requirements of Lynca Meats.
Results: Increased Storage Capacity and Operational Efficiency
The completed installation delivered significant improvements to Lynca’s storage and logistics capabilities.
Key benefits include:
- 5,500 pallet storage capacity within a single cold storage facility
- High-density storage with 100% pallet accessibility
- Improved energy efficiency within the freezer environment
- Increased storage capacity without expanding the warehouse footprint
- Enhanced stock control and product handling efficiency
- Built-in capacity for future storage expansion
Engineering Efficient Cold Storage Solutions
The Lynca Meats project demonstrates how LSE’s mobile pallet racking (MovoRack) technology can transform cold storage operations, enabling businesses to significantly increase storage capacity while maintaining operational efficiency.
By combining advanced storage engineering with high-density mobile racking systems, Logistics Systems Engineering continues to deliver innovative storage solutions tailored to the demanding requirements of the food processing and cold storage industries.
If your cold storage facility needs to increase capacity without expanding its footprint, Logistics Systems Engineering can design the solution.
Project Images & Illustrations
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