As cold chain logistics evolves, the demand for high-performance, automated environments continues to grow. One of the latest examples is the new lights-out, hypoxic frozen distribution centre in Hornby, Christchurch — a large-scale project that PHS Innovative has helped bring to life for Foodstuffs South Island.
From concept to collaboration
PHS Innovative became involved in the project through a consulting firm engaged by Foodstuffs South Island to explore automation options. Having worked successfully with the consultant on previous projects, the team was invited to respond to the tender and ultimately selected to deliver the materials handling solution in close coordination with the main build contractor.
What Foodstuffs South Island needed
The brief was clear:
- Fast, timely replenishment of pick faces for supermarket orders
- Maximum pallet density within a constrained footprint
- Vendor stockholding, allowing suppliers to store product onsite for just-in-time fulfilment
PHS Innovative was tasked with delivering a solution that could meet these objectives while integrating with Foodstuffs South Island’s new SAP warehousing system and working around a live, operating freezer at –25°C.
Our scope and solution
Led by Gareth McCloughen, General Manager of PHS Innovative, the team designed and delivered a high-density, fully automated storage and retrieval system (ASRS) tailored for the cold environment. The system features:
- Three large blocks of deep-lane racking
- Two aisle cranes operating between racking zones
- Supercapacitor satellite shuttles for deep pallet access
- Integration with both existing infrastructure and new enterprise software
The final configuration not only met but exceeded the original requirements for pallet capacity and throughput.
Engineering in extreme environments
A key challenge was integrating the automation system into an existing –25°C freezer that remained fully operational throughout. This required careful phasing, safety management, and detailed engineering to avoid disrupting live operations.
Even in the ambient-temperature greenfield warehouse, the complexity of the automation infrastructure — including aisle cranes and satellite shuttles — demanded precision coordination between all mechanical and software systems. The timing was further compounded by the client’s concurrent SAP transition, which added another layer of integration complexity.
Collaboration across the board
PHS Innovative coordinated with multiple project partners including Storepro (racking design and supply), Deltar (installation), Onsite Welding, and Concrete Solutions (grouting for crane infrastructure). At peak stages, up to 30 people were active on-site under PHS Innovative’s contract.
Despite significant shipping delays and global logistics disruptions, all installation milestones under direct PHS Innovative control landed on schedule — including the crane commissioning and racking build.
Built for resilience and efficiency
With capacity for 6,240 pallets, the lights-out facility is designed for high-throughput operation and minimal human intervention. This reduces the safety risks of working in sub-zero conditions, eliminates forklift damage, and enables faster, more efficient product replenishment.
As Gareth puts it: “Lights-out warehousing in a cold space isn’t just about efficiency — it’s about protecting people and getting more from every square metre.”
Looking ahead
As the demand for frozen storage grows across New Zealand and Australia, PHS Innovative is positioning itself as a trusted automation partner for the cold chain sector. The company continues to invest in innovation and is currently delivering further projects for major 3PL and food distribution partners.
“Automation is the future of cold storage,” says Gareth. “The benefits go beyond cost — they’re operational, environmental, and human.”
About PHS Innovate. From our engineering base in New Zealand, PHS Innovate offer customised materials handling products and systems across Australia, New Zealand, and the Pacific region. Whether you’re a multinational company with complex production lines or a smaller business looking to scale up, we build solutions that fit your specific needs. Contact us today to discuss your project.