Wodonga Rendering

The solution

This operating reality strengthened the case for a “dark warehouse” approach, in which the storage environment could operate with minimal human exposure. By deploying 2,520 pallet bulk storage locations across 9 levels serviced by Stow Atlas 2D shuttles, the operation shifted routine pallet movement away from forklifts and into an automated storage system designed to function reliably in harsh conditions. Inbound and outbound conveyors, paired with a vertical transport lift, ensured pallet flow could continue smoothly between levels without requiring people to travel through cold zones to move inventory.

To reduce exceptions that become harder to resolve in cold environments, the solution also incorporated profile checking and barcode scanning at key points in the flow. Profile checks prevented non-conforming or unstable loads from entering the system, while scanning ensured pallets were correctly identified throughout handling, both of which helped avoid time-consuming interventions that would otherwise require personnel to enter the -23°C area.

Finally, the operation was coordinated by the XY Logistics Warehouse Execution System (WES), interfacing with the customer’s WMS to manage tasking, prioritisation, and real-time equipment orchestration. This allowed the process to remain accurate and responsive while keeping the WMS as the system of record and critically, it reduced the need for human presence in the cold storage areas to only true exceptions and maintenance, rather than day-to-day execution.