Fruit Services Collective increases storage density with innovative Pallet Shuttle system from Dexion.

Near the Belgian-Dutch border, not far from Meer, is the state-of-the-art premises of Fruit Services Collective (FSC). The company was founded from the expertise of Special Fruit, a pioneer in the European market for ready-to-eat fruits and vegetables. Whereas FSC initially ripened fruit primarily for Special Fruit, it now serves a broader clientele in retail and foodservice.

FSC's core business is supplying 'ready-to-eat' fruit, with avocados as its main product. For this, the company uses the advanced Softripe technology. Unlike traditional methods, the ripening process is fully controlled via sensors and artificial intelligence. This enables uniform, organic ripening. The result? Better quality, longer shelf life and a natural preservation effect. Avocados are harvested unripe according to specific quality criteria and then stably transported to FSC, where controlled ripening takes place.

From empty shed to optimally equipped business

FSC is a young company that moved into an empty industrial building in early 2023. Willem-Jan Kwisthout, Head of FSC, was tasked with building the company from the ground up. "The challenge was great: setting up a completely new operation where the logistical flow and temperature regimes had to be optimal. An important starting point was the efficient use of space as well as energy."

In the second half of 2023, the cold rooms were built according to a box-in-box concept. Ripening started from April 2024, followed in June by the commissioning of the packing line. In the initial phase, ripened fruit was stored on the floor of the cold rooms - a temporary solution with a capacity of about 80 pallets per cell.

Looking for the best storage system

Thanks to his experience in the fruit industry, Willem-Jan Kwisthout knew the importance of making the best use of cold storage space. FSC examined various storage systems, including single-deep pallet racking (too much loss of space), mobile racking (limited accessibility), drive-in racking (less flexible) and automated pallet shuttle systems (too costly for the relatively low pallet volume). Roll-through racks also proved unsuitable because of the risk of tipping over at higher pallet stacks.

The final choice was an innovative mechanical pushback system with flat trolleys. Instead of an inclined plane, these systems work with four trolleys that are pushed on top of each other. The trolleys are sealed to meet hygiene requirements and function as a safe push-in system. The top trolley is pushed back when a new pallet is placed, after which the next trolley becomes available.

Collaboration with Dexion

For implementation, FSC sought an experienced partner. Dexion, which specializes in warehouse equipment, was eventually awarded the contract. "What convinced us was Dexion's commitment. They thought actively about solutions and implementation," Kwisthout said. For example, the pallet stops were already installed in the floor of all cold rooms, so that future placement of the racks could proceed faster and without disruption.

Efficiency and preparation

The switch from floor storage to racking required some adjustment from the staff. Properly placing pallets at height with reach trucks and storing by maturation batch requires more planning than random floor storage. FSC's use of three different pallet types also required extra attention.

Yet the benefits far outweighed the initial learning curve. Thanks to the new layout, approximately 440 pallets can now be stored per cold room. A whopping 550 percent increase over the original capacity!

Creative solutions for maximum utilization

A notable example of smart collaboration was the utilization of the full cell height. Coolers hang about 7 meters high, while the cell is almost 10 meters high. In consultation with installers and Dexion, a hinged frame was designed into the racking, which can be easily folded away for maintenance. Only the underlying pallets need to be temporarily removed.

Looking to the future

FSC will equip all four cold rooms with this system. Willem-Jan Kwisthout looks back with satisfaction: "We have realized an efficient, future-proof solution thanks to strong cooperation with our partners." Dirk Geets of Dexion agrees: "An empty warehouse offers unique opportunities. The vision and openness of the FSC team made this project special."