Application 10 · Where the finish is the specification
Cold storage racking: corrosion is capacity loss, slowly.
In a chiller or freezer, racking faces condensation on every temperature cycle, washdown chemicals, and frost that forms and melts at cut edges and connector welds. Corroded steel is steel with less section, and less section is less capacity — quietly, over years, in a structure nobody re-rates. That is why finish selection in cold storage is a structural decision, not a cosmetic one.
In brief
Cold storage racking must resist condensation from every temperature cycle, washdown and frost at cut edges and welds. Corroded steel has less section and therefore less capacity, which makes finish selection a structural decision rather than a cosmetic one.
- Hot-dip galvanising is the correct finish for chillers, freezers and washdown areas — galvanise the whole assembly, not just the frames.
- By volume efficiency: mobile racking, then radio shuttle, then drive-in, then push back. By value at typical Indonesian scale: drive-in.
- Cold store slabs may include insulation and under-floor heating, which changes anchor and baseplate design.
- Decide the racking while the cold room is still a drawing — lane depth and rack height set the room’s dimensions and refrigeration load.
01 — Finish selection
Powder coating or hot-dip galvanising
| Environment | Recommended finish | Reasoning |
|---|---|---|
| Dry ambient warehouse | Powder coating | Even, hard-wearing film; standard or custom colours |
| Chiller, 0 to 8 °C | Hot-dip galvanised | Condensation on every door opening and defrost cycle attacks coated edges first |
| Freezer, −18 to −25 °C | Hot-dip galvanised | Frost and defrost cycling, plus impact damage that exposes bare steel |
| Food washdown areas | Hot-dip galvanised | Frequent cleaning with water and detergent; zinc is sacrificial, paint film is not |
| Blast freezing zones | Hot-dip galvanised | Rapid, repeated thermal cycling is the harshest case in the building |
| Ante-rooms and docks | Galvanised or coated | Assess case by case; the temperature transition zone is often wetter than the cold room itself |
Galvanise the whole assembly, not only the frames: rails, brackets, decking, guards, carts and shuttle rails all corrode, and mixed specifications fail at the components you left out.
02 — System selection
Density ranked by refrigerated volume saved
Every cubic metre of aisle in a freezer is refrigerated continuously for the life of the building. That single fact reorders the usual system ranking.
| System | Floor used for storage | Rotation | Investment | Cold store verdict |
|---|---|---|---|---|
| Mobile racking | 80–90% | FIFO or LIFO free | Highest | Best volume efficiency; suits high value, lower pick rate |
| Radio shuttle | 60–85% | FIFO or LIFO | High | Very strong at scale and high throughput |
| Drive-in | 60–80% | LIFO | Moderate | The most common choice in Indonesia; best value per position |
| Push back | 60–75% | LIFO | Moderate to high | Good where the truck should stay out of the lane |
| Pallet flow | 60–80% | True FIFO | High | Where date rotation is mandatory |
| Selective | 30–40% | Free | Lowest | Only where SKU variety leaves no alternative |
Mobile and shuttle systems typically start to repay their cost above roughly 3,000 pallet positions, where refrigeration energy saved is large enough to cover the equipment. Below that, drive-in is usually the sound recommendation.
03 — Cold-specific design points
What changes inside a cold room
Airflow
Leave clearance to walls, ceiling and evaporators so cold air circulates and the room does not develop hot spots at the back of a block.
Floor detail
Cold store slabs may include insulation and under-floor heating. Anchor selection and embedment must respect that build-up — this is checked before design, not on site.
Visibility and impact
Cold, misted lanes raise impact risk. Systems that keep the truck out of the structure — push back, shuttle — reduce damage as well as operator exposure.
Battery performance
Shuttle and truck battery capacity falls at freezer temperature. Plan charging outside the cold room and provide spares.
Hygiene
Wire mesh decking rather than solid panels where cleaning and inspection matter; smooth galvanised surfaces are easier to keep clean.
Installation window
Racking is installed before the room is brought down to temperature wherever possible. Installing in an operating freezer is possible but slower and more expensive.
04 — Sectors we work with
Cold storage applications in Indonesia
- Frozen seafood and fisheries export, including blast freezing and holding rooms.
- Poultry and meat processing, where washdown and chiller humidity are constant.
- Dairy, bakery and short-shelf-life production, where rotation control decides write-offs.
- Frozen ready meals and food service distribution.
- Fruit, vegetable and horticultural chilled storage.
- Ice cream and confectionery, with tighter temperature and handling constraints.
- Pharmaceutical and vaccine cold chain, at 2–8 °C with validated conditions.
- Cold chain third-party logistics serving multiple clients from one room.
Questions buyers ask
Frequently asked questions
Why hot-dip galvanising rather than powder coating in a cold room?
Temperature cycling produces condensation, and moisture attacks coated cut edges, drilled holes and connector welds first. Zinc protects sacrificially even where the surface is scratched, so a galvanised structure keeps its section — and therefore its capacity — far longer.
Which racking system is best for a freezer?
By volume efficiency: mobile racking, then radio shuttle, then drive-in, then push back. By value for money at typical Indonesian scale, drive-in remains the most common choice. We compare all four on your pallet count, throughput and energy cost.
Does galvanising affect lead time?
Yes. Galvanising is an additional external process after fabrication, so allow extra time in the programme compared with powder coating. Confirming the finish early is the most effective way to protect your installation date.
Can racking be installed in a freezer that is already running?
Yes, but it is slower, requires shift planning around temperature and operator exposure limits, and costs more. Where the room can be warmed for the works, the programme is much shorter.
What about the floor in a cold store?
Cold store slabs often include insulation layers and sometimes under-floor heating. Baseplate and anchor design must account for that build-up, so we need the floor build-up detail before finalising the design.
Do you supply cold storage racking outside Java?
Yes. We have delivered to cold storage projects across 34 provinces, including fisheries and export facilities. Racking ships knocked down and installation crews travel with the shipment.
Talk to engineering, not a call centre
Building a cold room? Talk to us while it is still a drawing.
Racking layout decided early changes the room dimensions, the door positions and the refrigeration load. Brought in late, it has to fit whatever was built.