Mobile Pallet Racking Transforms Freezer Capacity for Grain Field Chickens
Engineering a High-Density Freezer Warehouse with Advanced Mobile Pallet Racking
When Grain Field Chickens required a new freezer storage facility capable of maintaining extremely low temperatures while maximising pallet density, the company partnered with Logistics Systems Engineering (LSE) to engineer a purpose-built cold storage solution.
The project incorporated the LSE MOVO 3008 Heavy Mobile Racking System, designed to safely operate in temperatures of −25 °C while delivering exceptional storage density and advanced automation control.
Through a carefully engineered combination of civil works, freezer construction, and PLC-controlled mobile racking, LSE created a highly efficient cold storage facility capable of storing 1,694 pallets with a total stored weight exceeding 2 million kilograms.
About Grain Field Chickens
Grain Field Chickens operates in the poultry processing and cold storage sector, where efficient and reliable freezer storage is essential for maintaining product quality and supply chain efficiency.
To support growing operational demands, the company required a new high-capacity freezer chamber that could maintain strict temperature conditions while maximising storage capacity within a limited building footprint.
Achieving this goal required more than simply installing racking — it required a fully engineered cold storage facility, from the foundations and floor construction through to the mobile racking system and automation controls
The Challenge: High-Density Storage in a -25°C Freezer Environment
Grain Field Chickens needed a storage solution capable of meeting several complex operational and engineering requirements.
The new freezer chamber needed to:
- Maintain consistent temperatures of −25 °C-
- Achieve maximum pallet density within the available warehouse footprint
- Support heavy pallet loads of up to 1,200 kg per pallet
- Provide safe operation in a frozen environment
- Integrate advanced PLC control systems and WMS connectivity
- Be engineered from the ground up, including civil works, flooring, and structural preparation
In addition, the project required precise coordination between construction, engineering, and racking installation to ensure the freezer chamber could support the substantial weight and movement loads associated with mobile racking systems.
The Solution: A Fully Engineered Mobile Racking (MovoRack) Freezer Facility
To meet these requirements, LSE designed and delivered a custom-built freezer warehouse incorporating the MovoRack 3008 Heavy Mobile Racking System.
The system was divided into two mobile racking blocks, combining mobile and static pallet racking to maximise storage capacity while maintaining operational flexibility.
Mobile pallet racking operates on rails embedded in the warehouse floor, allowing the racks to move laterally so that only one working aisle is opened at a time. This eliminates unnecessary aisles and dramatically increases storage density while still providing direct access to every pallet.
Technical Data: Grain Field Chickens Freezer Warehouse
Mobile Pallet Racking (MovoRack)
| Feature | Specification |
|---|---|
| Client | Grain Field Chickens |
| Industry | Poultry Processing & Cold Storage |
| Location | South Africa |
| System Installed | LSE MovoRack Heavy Mobile Racking System |
| Operating Temperature | −25 °C |
| Warehouse Size | ± 1 600m2 |
| Mobile Racking Blocks | 2 Blocks |
| Block 1 Configuration | 5 Mobile Bases with Statics |
| Block 2 Configuration | Block 2 Configuration 4 Mobile Bases with 1 Double and 3 Single Static Rows |
| Static Pallet Locations | ± 500 Pallets |
| Mobile Pallet Locations | ± 2 000 Pallets |
| Total Pallet Capacity | ± 2 800 Pallets |
| Total Stored Weight | 3 200 000kg |
| Total Racking Equipment Weight | 80 000kg |
Technical Data: Grain Field Chickens Freezer Warehouse
Mobile Pallet Racking (MovoRack)
| Feature | Specification |
|---|---|
| Client | Grain Field Chickens |
| Industry | Poultry Processing & Cold Storage |
| Location | South Africa |
| System Installed | LSE MovoRack Heavy Mobile Racking System |
| Operating Temperature | −25 °C |
| Warehouse Size | ± 1 600m2 |
| Mobile Racking Blocks | 2 Blocks |
| Block 1 Configuration | 5 Mobile Bases with Statics |
| Block 2 Configuration | Block 2 Configuration 4 Mobile Bases with 1 Double and 3 Single Static Rows |
| Static Pallet Locations | ± 500 Pallets |
| Mobile Pallet Locations | ± 2 000 Pallets |
| Total Pallet Capacity | ± 2 800 Pallets |
| Total Stored Weight | 3 200 000kg |
| Total Racking Equipment Weight | 80 000kg |
Wire Mesh Decking System
To ensure safe pallet storage and product support across all racking levels, LSE installed 1,602 wire mesh decks throughout the system.
Wire Mesh Decking
| Feature | Specification |
|---|---|
| Deck Quantity | 2 000 Decks + 500 Grating Levels |
| Type | Wire type with Omega Supports |
| Capacity | 2 500kg UDL per Level |
| Finish | Powder Coated |
| Deck Design | Front and Rear Waterfall |
| Total Decking Weight | ± 20 000kg |
The mesh decking provides enhanced load distribution, improved pallet stability, and additional safety across all beam levels and mobile bases.
Advanced Automation and Safety Systems
LSE’s MovoRack system was equipped with a Siemens PLC control system, enabling safe, efficient, and automated operation of the mobile racking system.
PLC Capabilities Include:
- Remote control of all mobile racking block
- Forklift counter and identification system
- Advanced aisle lighting control per block
- Park (night) mode for air circulation
- Fire position mode
- Order-pick position mode
- Remote monitoring and diagnostics support
- WMS interface integration
Each mobile base also includes a front-mounted control panel for manual operation, complete with an emergency stop button.
Safety features
To ensure safe operation within the freezer environment, the system incorporates multiple safety mechanisms:
- Safety light barriers on both sides of the mobile system
- Emergency stop functionality on every base
- PLC-controlled aisle movement
- Safety logic preventing movement while forklifts are present in the aisle
Project Execution: From Foundations to Commissioning
The Grain Field project required a carefully coordinated multi-phase installation process.
Phase 1 – Foundations
Preparation and casting of perimeter wall foundations designed to support the heavy mobile racking loads
Phase 2 – Structural and civil works
Final floor base levels were compacted to engineering specifications, while the steel structural extension for the cold room and PODS was installed. Insulated wall panels were then installed.
Phase 3 – Roofing
Insulated roof panels were delivered and installed, followed by IBR Chromadek roof cladding.
Phase 4 – Internal preparation
Electrical and lighting systems were installed, structural pillars sealed, and the floor prepared for insulated panels and MOVO rail placement.
Phase 5 – Rail foundations
Reinforcement bars were installed prior to pouring the concrete foundations for the mobile rails. Once cured, LSE engineers precisely positioned and secured the MOVO rail system.
Phase 6 – Services and PODS
A void sprinkler system was installed between the roof structure and insulated panels. Reinforcement bars for the final floor slab were installed, and the cold room PODS were delivered and positioned by crane.
Phase 7 – Final flooring
The final concrete floor slab was poured, floated, and polished to meet engineering specifications.
Phase 8 – MOVO installation
Mobile bases were assembled and installed onto the rails, followed by the installation of racking structures, PLC motors, control cabling, and safety barriers.
Phase 9 – Commissioning
Mesh decks were installed, final system checks were completed, and the facility was commissioned and handed over to Grain Field Chickens.
Results: A High-Performance Freezer Storage Facility
The completed installation delivered significant operational and storage benefits.
Key outcomes include:
- Up to double the storage capacity compared to conventional racking
- 1,694 pallet positions within a single freezer chamber
- Safe and reliable operation at −25 °C
- Advanced automation with PLC control and WMS integration
- Optimised warehouse space without expanding the building footprint
- A robust engineering solution designed for long-term performance
Customer Handover
The Grain Field project was successfully completed within the required budget and timeframe, delivering a fully operational freezer warehouse equipped with the LSE MovoRack 3008 Heavy Mobile Racking System.
LSE would like to thank all teams involved for their dedication, engineering expertise, and coordination throughout the successful delivery of this complex cold storage project.
Engineering Cold Storage Solutions for the Future
The Grain Field Chickens project demonstrates how LSE’s engineering-led approach to mobile pallet racking (MovoRack) enables businesses to unlock significant storage capacity within temperature-controlled environments — without expanding their building footprint.
From civil works and freezer construction to PLC-controlled MovoRack mobile racking, Logistics Systems Engineering delivers fully integrated storage solutions designed for safety, efficiency, and long-term performance.
If your cold store or warehouse is running out of space, energy efficiency, or flexibility, contact Logistics Systems Engineering to explore how a mobile racking solution can transform your operation.
Project Images, Illustrations & Videos
Ask an Expert
I would like a Quote for Mobile Racking (MovoRack)
Please Fill in the Form Below. Specify the Product Information you Require or How LSE can Help you.
