Leading Polish cold-chain 3PL Frigo Logistics embraces automation

Frigo Logistics: Experts in temperature-controlled services

Frigo Logistics is a leading Polish logistics provider specialising in temperature-controlled food products. The company offers distribution, transport and warehousing services for deep-frozen, chilled, ambient and liquid foods. It also provides international ocean, air and rail freight services. Founded in 2001, it has a transport fleet of 100 company-owned vehicles and more than 450 operated by logistics partners. Since 2004, the business has been part of Japan’s Nichirei Logistics Group Inc., the country’s market leader and one of the world’s largest providers of food logistics services.

Frigo Logistics has enhanced the quality of its third-party-logistics (3PL) services at its distribution centre (DC) in Nowy Dwór Mazowiecki. Mecalux equipped the facility in east-central Poland with automation solutions and its Easy WMS warehouse management system. The project expands storage and shipping capacity for products kept at temperatures between -18 °C and -24 °C.

The 24,500 m² DC serves as a strategic hub for deep-freeze distribution throughout Poland. Frigo Logistics works with the country’s five largest retail chains and around 100 food manufacturers.

“We manage our clients’ entire supply chain, from warehousing through to the transport and distribution of frozen, chilled and ambient food products. Every day, we deliver to more than 4,500 locations across Poland while maintaining the cold chain at every stage,” says Maria Piotrowska, Project Manager at Frigo Logistics.

The DC consists of three integrated areas: a 36-metre-high automated warehouse with a 15,000-pallet capacity, a storage zone with 5,000 slots and a shipping area with 11 loading docks. To connect these spaces without compromising temperature control, the facility is equipped with airlocks that serve as thermal transition zones, minimising cold loss.

High-bay automation at -24 °C

The automated storage and retrieval system (AS/RS) has enabled Frigo Logistics to achieve 99.9% order reliability during fulfilment and shipping. “Automation helps us maintain a consistently high level of service quality,” says Piotrowska.

Housed in a rack-supported warehouse at the heart of the facility, the AS/RS features six aisles of double-deep racking across 12 storage levels. The high-density structure operates continuously at -24 °C and accommodates 15,000 pallets. Stacker cranes equipped with telescopic forks ensure a continuous flow of goods between receiving, storage and dispatch.

The automated warehouse also absorbs seasonal demand peaks without requiring additional resources or affecting turnaround times. “The AS/RS allows us to process more orders in less time,” says Piotrowska. Logistics automation also improves working conditions by reducing operators’ exposure to extremely cold temperatures.

To safeguard stored products, the warehouse incorporates an inert gas fire suppression system that lowers oxygen levels to reduce the risk of combustion. The building structure rests on a concrete foundation slab reinforced with 190 tonnes of steel and 2,000 m³ of concrete, providing the stability required for the entire AS/RS.

Integrated with manual storage and dispatch

The automated warehouse is connected to a manual storage zone through a conveyor system and a transfer car. This area, equipped with selective pallet racking and Movirack mobile pallet racking, provides capacity for an additional 5,000 units. The configuration supports the diverse requirements of multiple Frigo Logistics clients. It enables the 3PL to manage fast-moving products, multi-SKU orders and goods requiring direct pallet access within the same zone.

The shipping area, located next to the manual storage space, features 11 loading docks. This layout streamlines order fulfilment and distribution to more than 4,500 delivery points across Poland. “Our consistently reliable, on-time deliveries result from meticulous route planning, advanced fleet management, collaboration with more than 150 carriers and efficient warehouse control supported by modern systems and well-organised processes,” says Piotrowska.

Operational accuracy with Easy WMS

Mecalux’s Easy WMS warehouse management system coordinates operations across the facility by linking the physical flow of pallets with the data needed to track and control every movement. The software automatically assigns storage locations according to product type and demand while maintaining real-time inventory visibility. It directs every pallet movement, from receiving through dispatch.

“Access to real-time data allows us to make quick decisions and respond rapidly to changes in demand,” says Piotrowska. “The communication between our corporate software and Easy WMS ensures smooth operations while meeting the highest quality standards.” The Mecalux solution provides full traceability from receiving through shipping, a key requirement for compliance with food safety regulations.

Temperature-controlled logistics as a competitive advantage

With its new automated DC, Frigo Logistics has reinforced its position as one of Poland’s leading 3PL providers for deep-frozen food. Piotrowska says: “Our priority is to maintain strict temperature control and preserve the cold chain throughout every stage of the logistics process.”

By combining automation, manual storage systems and specialised software, Frigo Logistics can coordinate daily shipments with greater accuracy while supporting future growth. “Automation has significantly improved service quality and process efficiency while reducing the time required to complete warehouse operations,” says Piotrowska.

Automation helps us maintain a consistently high level of service quality.