In order to maintain proximity to existing customers and enable further growth at its current location, the logistics service provider expanded its deep-freeze capacities in the Münsterland region with Stöcklin in 2025 and is planning to modernize the associated old facility with a focus on efficiency.
Expansion of an automated deep-freeze warehouse to include an adjacent, state-of-the-art, sustainable high-bay warehouse
Planning and implementation of a fully automated, four-aisle, 42-meter-high channel warehouse for 32,000 additional pallet spaces in deep-freeze storage, including four MASTer 2042 series storage and retrieval machines and heavy-duty PowerShuttles for multi-depth storage
Direct connection to existing capacities and integrated control of the entire facility, which comprises a total of 100,000 storage locations; all operating devices are equipped with energy-saving modes, recuperation, and grid feed-back as standard, reducing energy consumption by more than 20 percent
The opportunity to retrofit the old system in order to leverage performance and sustainability potential there as well
Twelve years ago, the internationally active deep-freeze logistics service provider NewCold in Rheine commissioned what was then Germany's largest automatically operated deep-freeze warehouse. In 2025, capacity was increased by 50 percent thanks to an extension: the high-bay plant grew by 32,000 to more than 100,000 pallet spaces in deep-freeze storage – on just one soccer field of additional space.
Together with its long-standing intralogistics partner, the Stöcklin Group, an additional four-aisle channel storage system with a powerful operating concept was created. Four MASTer 2042 series storage and retrieval machines, each 42 m high and designed for narrow aisles, move with centimeter precision between the compact rows of racks. Each storage and retrieval machine works with a heavy-duty PowerShuttle in its own aisle, which is capable of storing and retrieving pallets at multiple depths. Together, they enable high storage density and achieve a throughput of up to 6,000 pallets per day (24/5) at -23 °C, and six or seven days a week if required.
A major challenge was the construction and connection of old and new during ongoing operations. The new warehouse is directly adjacent to the old one, separated only by a fire wall with a few airlocks. The construction work took two years. Even during the peak summer season, it was important to ensure that no cold air was lost and to minimize the flow of oxygen and moisture into the inertized building whenever the cooling shell of the existing hall had to be opened for structural connection or integration of the new conveyor systems. Furthermore, a great deal of attention to detail was required to seamlessly integrate the plant into the existing processes on the software side.
With a ready-to-use replacement shuttle and data-driven maintenance and servicing, NewCold Rheine achieves almost 100 percent availability – with 20 percent less energy consumption. The plan is to work with Stöcklin to transfer the technological advantages of the new plant to the existing facilities.
