Temperature-Controlled Warehouse Operations

Temperature-controlled automation is becoming essential across a range of industries—from grocery and food logistics to pharmaceuticals, electronics, and high-value consumer goods. These sectors share a common challenge: how to safely, efficiently, and cost-effectively store and move temperature-sensitive products across complex fulfillment networks.

But not every automation system is built to perform in extreme temperature environments. From sub-zero frozen zones to high-humidity chilled areas, the materials, controls, and system design must be purpose-built to maintain reliability and product integrity.

For grocery logistics, the rise of curbside pickup and home delivery has accelerated demand for micro-fulfillment centers (MFCs). For others, it’s about regulatory compliance, product integrity, and operational speed. In every case, warehouse automation in temperature-controlled environments is proving to be a competitive advantage.

Unlocking Temperature-Controlled Automation

Managing temperature-controlled environments across the supply chain is a shared challenge for many industries, from fresh food and grocery to pharmaceuticals, medical devices, and temperature-sensitive electronics. Items must be handled, stored, and transported based on type, expiration dates, and regulatory compliance.

Automating your warehouse operations is the only way to maintain an effective fulfillment strategy. End-to-end automation enables your company to optimize food storage and material handling.

Once in place, automated solutions provide several short- and long-term benefits.

Lower Operational Costs: Energy-efficient automated systems cut down on the high cost of temperature-controlled storage facilities while promoting waste reduction and reducing your reliance on costly manual labor.
Faster, More Efficient Throughput: Automation enables you to meet customers’ demands by achieving fast, error-free picking, packing, and delivery.
Enhanced Product Integrity and Compliance: Automation helps maintain precise environmental conditions for sensitive goods, guaranteeing compliance with industry-specific regulations and protecting product quality.
Employee Retention: Automated systems create attractive opportunities for skilled workers in a sector traditionally known for grueling working conditions and high turnover.

Automated systems set your company up for scalability in an industry that’s projected to undergo massive growth.

[Translate to North America:] warehouse operations

Key Automation Solutions for Temperature-Controlled Facilities

Across industries, temperature-controlled facilities require intelligent automation strategies to maintain compliance, protect product quality, and maximize throughput. Optimizing your operation in an ambient, refrigerated, or frozen warehouse requires a strategic approach combined with innovative automation and software.

Storing and picking food and other temperature-sensitive items while maintaining temperature requirements is one of the most critical functions of cold storage operations across industries. An ASRS makes this easy by facilitating precise inventory movements within temperature-controlled environments like chilled or frozen storage. Smart robots move through an ASRS to retrieve items for orders, limiting the need for manual labor and speeding the material handling process.

Beyond speed and temperature control, ASRS solutions enable real-time inventory visibility and traceability, which is critical for managing expiration-sensitive goods, serial tracking, or regulatory compliance. Whether prioritizing earliest expiration dates for perishables or ensuring chain-of-custody for medical products, ASRS plays a vital role in reducing spoilage, recalls, and inventory shrinkage.

Managing material flow in temperature-controlled environments introduces complexity, especially when safety, compliance, and precision handling are required. Automated conveyors and robotics form an integrated network that unifies operations from ambient to frozen environments across industries.

Robotic arms pick split case orders in any temperature zone, using specialized grippers to handle items without damaging them. Together, these automated systems enable quick, accurate order fulfillment within controlled environments without compromising safety or product integrity.

Outbound logistics can be tricky in temperature-controlled fulfillment centers. While ambient and chilled products could be consolidated onto pallets in a chilled temperature zone, it is a labor-intensive task.

Automated palletizing systems reduce manual labor and support high-throughput outbound logistics across temperature-controlled zones. In grocery settings, they build mixed-case pallets while separating frozen, chilled, and ambient goods to prevent cross-contamination. In other industries like pharma or electronics, automated palletizers protect product integrity by controlling stacking pressure, spacing, and container insulation. Across the board, they optimize truck loading, reduce product damage, and speed up last-mile logistics.

Maximize Your ROI with Software Integration

If automated equipment is the workhorse of your temperature-controlled operation, software is the command center. Across industries, a robust Warehouse Management System (WMS) orchestrates critical workflows—directing inventory, managing temperature-specific storage, and safeguarding regulatory compliance.

A WMS is invaluable for managing perishable food items. It provides real-time inventory tracking, ensures the right items are picked for customer orders, and directs incoming goods to the right storage environment.

A Warehouse Execution System (WES) is the software layer underneath the WMS. It monitors and controls each automated system within the required temperature-controlled environment while assigning tasks, managing picking requirements, and pinpointing bottlenecks. In a nutshell, WES supports optimal workflow in frozen, chilled, and ambient warehouses.

Together, WMS and WES improve system uptime with predictive maintenance and generate data-driven insights that help you optimize throughput, reduce downtime, and make more informed operational decisions.

Industry Applications and Case Scenarios

TGW Logistics has partnered with companies worldwide to solve their logistics challenges with state-of-the-art automation, each with unique regulatory, environmental, and throughput demands. We understand the complexity of temperature-controlled environments and take a strategic approach to meeting our partners’ short- and long-term goals.

Cold Chain Flexibility

Wiesenhof, one of Germany’s largest suppliers of poultry meat, decided to incorporate innovative cold chain logistics solutions into its new processing and distribution center. The goal was to boost distribution, enhance product availability, and achieve operational flexibility.

TGW Logistics helped bring Wiesenhof’s vision to life by implementing material handling systems in two temperature zones. An automated palletizing station, three gantry robots, and a shuttle warehouse support the consolidation of in-house products and external goods in one distribution center.

Learn more.

Grocery Distribution Efficiency

Frisco, a leading online grocery retailer in Poland, partnered with TGW Logistics after reaching their fulfillment capacity. We provided automated solutions for a new high-capacity facility with four temperature zones.

A conveyor system separates inbound goods into dry and refrigerated totes and transports them to a storage warehouse. Shuttles and ergonomic workstations make order picking fast and easy, and palletizing robots prepare customer orders for rapid home delivery. This system supports cost-efficient operations, reduces food waste, and enables Frisco to handle a higher order volume.

Learn more here.

Safe Storage and Transportation for Electronic Devices

In the consumer electronics sector, many high-value components, like batteries, semiconductors, and sensors, must be stored and shipped within defined thermal ranges to prevent damage or degradation.

TGW Logistics has partnered with electronics manufacturers to implement temperature-controlled storage and fulfillment systems that streamline material handling and minimize electrostatic and thermal risks through robotics and insulated storage designs.

Medical Device Fulfillment at Scale

Richard Wolf, a global manufacturer of medical devices and endoscopy systems, partnered with TGW Logistics to centralize and automate its distribution operations. The solution included a shuttle system, ergonomic workstations, and anti-static conveyor technology to support the safe handling of sensitive components.

TGW Logistics’ automated system maintains stable, controlled conditions critical for storing and moving sensitive medical products—aligning with the same principles as temperature-controlled logistics. With a design built for expansion, the system allows Richard Wolf to scale its operations as demand grows.

Learn more here.

TGW Logistics: Your Partner in Temperature-Controlled Fulfillment

Scalability is essential for any operation handling temperature-sensitive goods. Adapting to higher demand, omni channel workflows, and supply chain challenges requires a strategic mindset and flexible warehouse operations that support temperature-controlled environments.

TGW Logistics is much more than an automation provider. We design, integrate, and support full-scale logistics systems that deliver consistent performance in ambient, chilled, and frozen environments. Our experts understand the complexity of temperature-controlled storage and fulfillment centers and will work closely with you to future-proof your system.

We also help you achieve successful post-automation operations with on-site or remote support services designed to keep your system running at peak performance. Our work doesn’t stop after implementation. It’s our goal to grow alongside you and remain your trusted partner as you scale.

Optimize Your Warehouse Operations With Automated Solutions

With TGW Logistics, you can elevate your temperature-controlled operations, whether you're managing groceries, pharmaceuticals, electronics, or other temperature-sensitive goods. Our automation solutions are designed for precision, scalability, and long-term performance across industries.

Contact us today to explore how TGW Logistics can help you transform complexity into competitive advantage.

The Business Case for Temperature-Controlled Automation in Grocery and Beyond