Ceratec supplies highly automated solutions for Coldo’s world’s tallest frozen food warehouse

With an impressive capacity of 60,000 pallets and a height of 47 meters, the new frozen-food warehouse of West Flemish company Coldo ranks among the most advanced logistics facilities in Europe. For the intralogistics automation of the warehouse, the client turned to Ceratec. Project Manager Maarten Vanoverberghe looks back on a technically challenging project in which customization, collaboration, and efficiency were key.

As a Belgian family-owned company—headquartered in Ploegsteert—Ceratec is the leading smart engineering partner for automation solutions across a wide range of industrial sectors. Through its Intralogistics Solutions business unit, the company develops systems for goods storage, transport, and picking. These range from small-scale applications to fully automated warehouses.

“Our strength lies in flexibility and custom engineering,” says Maarten Vanoverberghe. “We combine our own solutions with specialized handling machines and software, tailored to the customer’s needs. Because we’re a family-owned business, with short lines of communication and direct interaction, we can adapt quickly and provide targeted solutions.”

Ceratec was involved in the Coldo project from the very beginning. The request went beyond mere implementation: the company actively contributed ideas regarding the entire layout of the warehouse.

Engineering under extreme conditions

Cold’s impressive frozen-food warehouse presented unique challenges in terms of mechanical and electrical installation. This was due not only to the building’s scale and height, but also to the low temperatures and structural constraints. Ceratec therefore worked closely with other partners to arrive at a workable and efficient solution.

“You have to take everything into account: dimensions, concrete structures, temperature differences, and their impact on machinery,” explains Vanoverberghe. “That requires a thorough engineering approach.”

“One concrete example we implemented is the integration of an automatic loading and unloading system for trucks. This ATU system (Automatic Truck Unloading, ed.) ensures that pallets are loaded onto and unloaded from trucks with virtually no manual intervention. Its implementation required precise coordination with the available space and logistics flows.”

Investing with a focus on returns

One notable aspect of the project was the critical assessment of the return on investment. Automation offers many possibilities, but not every solution is necessary at every moment.

“For example, we suggested to the client that they install two ATU lines so that two trucks can be unloaded at the same time,” says Vanoverberghe. “Coldo opted to install one lane for now, but to keep space available for a second one. This approach reflects a well-thought-out, phased investment strategy.”

That same line of thinking continues today, particularly with regard to the implementation of layer picking. In this process, goods are picked by robotic grippers layer by layer to fill containers more efficiently.

Technical masterpieces on the construction site

In addition to the technical challenges, the project also involved some spectacular moments during construction. For example, a special crane was used to install the rack lifts. “That crane could reach up to 100 meters high and 60 meters wide. Those are the moments when you really realize just how large and complex a project like this is,” Vanoverberghe recalls.

“Our Ceratec team worked on-site in Kuurne for six to seven months. We remain involved in the project to this day, providing aftercare and making optimizations. This ranges from minor adjustments, such as tightening chains, to preparing for additional automation.”.

Collaboration as a Key to Success

According to Vanoverberghe, the strong collaboration among all partners was a decisive factor. “We worked with various parties who already knew each other and were well attuned to one another. That fosters trust and smooth communication, which is crucial for projects of this scale.”

For Ceratec’s Project Manager, the project is a testament to the smart engineering offered by the family-owned company: “We are proud to have contributed to a solution that offers maximum storage density and high throughput. This is exactly where we want to make a difference.”