Breaking New Ground: India’s First ASRS Temperature-Controlled Facility

Addressing a significant gap in the supply chain of perishable goods, Godwitt developed India’s first Automated Storage and Retrieval System (ASRS) temperature-controlled storage facility in Dholasan. Currently occupied by Indicold, this facility set new benchmarks in temperature-controlled storage solutions.

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It later became the catalyst for transforming our underutilized warehouse in Detroj into a temperature-controlled facility. By leveraging innovative vertical design, global best practices, and rapid retrofitting, we delivered scalable, efficient, and automated solutions tailored to meet market needs.

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Introduction

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At Godwitt, innovation is at the heart of our industrial real estate solutions. When Indicold approached us with the need for advanced temperature-controlled facilities for McCain, we saw an opportunity to reform the fragmented temperature-controlled storage solutions in India. 

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The projects encompassed the development of a state-of-the-art ASRS facility in Dholasan and the retrofitting of a dormant warehouse in Detroj, ensuring the highest standards of efficiency, scalability, and automation.’cdd

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Problem Statement

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Temperature-controlled facilities are a critical infrastructure in the supply chain for perishable goods. They require optimized space utilization, temperature precision, automation, and higher throughput to ensure efficient operations.  

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Automated and scalable systems are imperative to meet these requirements and ensure smooth operations. As such traditional warehouses fall short when it comes to storage of perishable goods, leading to inefficiencies and wastage.

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Godwitt addressed these critical gaps in the supply chain through two projects: (i) Soko by Godwitt - Dholasan, (ii) Soko by Godwitt - Detroj

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What We Overcame

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Temperature-controlled facilities face unique challenges due to their precision requirements. 

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We encountered these complexities head-on during the development of two distinct projects: building India’s first vertical ASRS facility available on lease in Dholasan and retrofitting an underutilized warehouse in Detroj to meet regional demands.

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For Godwitt’s projects, specific issues needed tailored solutions. 

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Soko by Godwitt - Dholasan (October 2023 - July 2024)

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Soko by Gowitt-Dholasan was our first project in the spectrum of temperature-controlled storage solutions. While stepping into a new domain comes with its own set of challenges, we encountered additional hurdles due to the specificity and precision requirements of a temperature-controlled storage facility.

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The available land parcel was limited, necessitating a vertical design to maximize storage capacity. Ultra-low temperatures of -25°C and high throughput requirements for peak operations posed significant engineering and operational challenges.

1. Limited Land Availability: The limited availability of the land placed structural complexities. It demanded a vertical design that could maximize space without expanding horizontally. 

2. Height Restriction: Government regulations capped the structure height at 30 meters. However standard vertical ASRS facilities require more height for stacker crane operations. Stacker cranes were integral to ensuring the required throughput. This required some innovative design adaptations that would allow us to comply with government regulations without compromising the throughput.

3. Engineering Complexity: Maintaining sub-zero temperatures of -25° introduced the challenge of frost formation under the RCC structure.

4. Temperature Gradient Management: Gradual cooling from ambient conditions (40°C) to -25°C had to be meticulously planned to prevent structural stress, condensation issues, and damage to the facility’s infrastructure.

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Godwitt Solutions

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• Design Innovation: To maximize storage capacity and throughput, Godwitt employed a fully automated vertical ASRS system. By integrating stacker cranes and shuttles, the design optimized vertical space utilization, making it one of the most efficient temperature-controlled storage facility setups in India.

• Excavation for Height Optimization: To overcome the 30-meter regulatory height cap, the team excavated 3 meters underground, creating additional usable vertical space. This solution allowed for the required 33-meter height, ensuring the facility met operational throughput demands without compromising compliance.

• Advanced Insulation Strategies for Sub-Zero Operations: To prevent frost accumulation beneath the RCC structure, insulated cables were incorporated, ensuring long-term structural integrity.

• Thermal Engineering Excellence: A gradual cooling plan was devised to mitigate structural stress caused by rapid temperature changes. This involved precision engineering to maintain uniform cooling and prevent thermal expansion or contraction-related damage.

• Collaboration with Global Experts: Godwitt partnered with international leaders like Craftsman Automation, Antes, and Spantech to ensure that the project adhered to global best practices in ASRS technology and temperature-controlled storage facility design.

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Setting New Standards

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The Dholasan ASRS facility now stands as India’s first temperature-controlled storage facility, setting a precedent for scalable and high-efficiency operations. 

• India’s first ASRS temperature-controlled storage facility became operational in July 2024.
• Achieved high throughput, reduced wastage, and improved cost-efficiency through automation.
• Set a benchmark for future temperature-controlled facilities in the region.

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Soko by Godwitt - Detroj: Pioneering Retrofitting

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At Detroj, Godwitt took on the ambitious task of converting a 1,10,000 sq. ft. warehouse into an insulated, temperature-controlled environment—optimizing throughput, energy efficiency, and automation to meet industry needs.

1. Retrofitting Challenges: Adapting a 1,10,000 sq. ft. conventional warehouse into an insulated temperature-controlled storage facility required extensive modifications, including reinforcing the structure for sub-zero operations.

2. Regional Adaptation: The facility was transformed into a temperature-controlled environment designed to cater to the bulk freezing requirements of the industry. This meant optimizing for high-throughput and quick turnaround while ensuring minimal energy consumption.

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Godwitt Solutions

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• Rapid Retrofitting: Recognizing the urgency of market needs, the team focused on quick and efficient retrofitting. A phased approach was adopted, prioritizing insulation and automation upgrades for immediate operational readiness.

• Localized Solutions: Unlike the high-tech vertical ASRS system in Dholasan, the Detroj facility adopted semi-automated systems tailored to the specific needs of the regional potato processing industry. Simplified racking and a 4-way shuttle system were employed to handle bulk freezing and storage with efficiency.

• Energy Efficiency: By enhancing insulation and optimizing refrigeration systems, the facility was designed to minimize energy costs while maintaining consistent sub-zero temperatures.

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A Game-Changing Transformation

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The Detroj facility’s transformation demonstrates the power of innovative retrofitting in meeting urgent market demands. 

• A dormant warehouse is now a thriving temperature-controlled facility.
• Enhanced bulk freezing efficiency, significantly improving service for local potato processors.
• Leveraged existing infrastructure to create scalable solutions with a minimal lead time of just 3 months.

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By integrating advanced automation, strategic design, and rapid execution, Godwitt successfully delivered temperature-controlled storage solutions that are redefining industry standards. 

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These projects not only optimized storage and energy efficiency but also reinforced Godwitt’s position as a leader in industrial real estate innovation.