Automated Pallet Freezer Storage System - Central NSW, Australia

Intelligent Cold-Chain Automation by Pac-Technologies

Pac-Technologies has engineered and delivered a fully automated freezer storage and retrieval system for a leading abattoir in Cootamundra, NSW — a system that functions as a giant intelligent vending machine for pallets. Designed to operate reliably in extreme sub-zero environments (–27 °C), the solution combines advanced automation, safety, and redundancy to maximise uptime and throughput in one of the most demanding industrial settings.

System Overview

At the heart of the system are two high-performance pallet elevators, nine storage levels, and a series of precision-controlled conveyors, transfer systems, and shuttles.

Pallets are loaded at ground level, automatically dimensioned, scanned, and verified against the Warehouse Management System (WMS) before entering the freezer. The WMS directs each pallet to an optimal storage position, ensuring traceability and inventory accuracy in real time.

Each pallet movement, from infeed to storage to retrieval, is coordinated by a Siemens S7-1500 F PLC and a custom WinCC interface. This setup provides operators with complete visibility and control over all system functions. The system’s redundant dual-elevator architecture allows either lift to perform both infeed and outfeed duties, maintaining continuous operation even during maintenance or component downtime.

Key Features

• End-to-End Automation – Seamless handling from pallet induction to final dispatch.

• Dual-Elevator Redundancy – Either lift can manage infeed or outfeed, ensuring no single point of failure.

• High-Speed Vertical and Horizontal Transport – Coordinated elevator and shuttle movement for rapid pallet exchange.

• Integrated WMS Communication – Real-time barcode and weight validation for complete product traceability.

• Safety by Design – Light curtains, emergency stops, interlocks, and monitored roller doors for operator protection.

• Optimised for Extreme Environments – Components and logic designed for reliable operation at –27 °C.

Business Benefits

• Increased Throughput – Continuous, automated pallet flow reduces manual handling and idle time.

• Improved Safety – Minimal human exposure to cold environments and moving equipment.

• Enhanced Product Integrity – Rapid, controlled transfers maintain cold-chain compliance.

• Reduced Downtime – Intelligent redundancy and diagnostic HMI interfaces minimise disruption.

• Scalable & Customisable – Modular control logic allows adaptation for future expansions or additional lines.

Outcome

The Cootamundra installation showcases Pac-Technologies’ capability to deliver complex, safety-critical automation systems that combine industrial reliability with cutting-edge control engineering.

From concept and design through PLC programming, HMI development, and commissioning, PAC Technologies provides end-to-end automation expertise — empowering clients with smarter, safer, and more efficient facilities.