Most people don’t give a second thought to how (or when) the food on their table was grown or where it was processed and stored. If you decide to learn more about how that hamburger bun got into your hands, you will discover that the process of making, storing, and delivering that delicious bun is complex and has many moving parts.
One of the most important factors of that process is cold storage. The cold chain logistics and transportation systems of today span all the way from the fields to the fast food chains and supermarket shelves throughout the country. Here we will dive deeper into the role of a freezer warehouse and other cold storage facilities in the food industry.
What Is Cold Storage?
Cold storage refers to a storage facility – usually, a large warehouse that can be temperature-controlled so that perishable goods like dairy, proteins, frozen foods, fresh produce, etc., can be stored in a way that extends their shelf life. Food products that spoil quickly or require refrigeration need temperature control so they can be preserved after manufacturing or harvest, and can be supplied throughout the year even when there is no production output.
Cold storage prevents significant economic losses due to spoilage and allows us to get our favorite food items year-round.
Cold Chain Logistics 101: How It Works in the Food Industry
Now you know that cold storage is the storage of temperature-sensitive products that prevent them from deteriorating. It also ensures food adheres to applicable regulations and laws.
A cold chain, on the other hand, is a supply chain network made up of refrigerated manufacturing, storage, and distribution activities, along with related logistics and equipment. The purpose of all these components is to maintain the quality of perishable products through a desired low-temperature range. Obviously, cold storage warehousing is only one part of a cold chain; together, all of the components extend the shelf life of products, such as frozen food, seafood, fresh agricultural produce, pharmaceutical products, chemicals, and more.
The cold chain logistics include cold storage warehouses, refrigerated transportation (mainly trucks), freezers for retail, and so on. The network of these temperature-controlled facilities makes it possible for the food industry to be so efficient in the US whether it is meat, dairy, fresh fruits and vegetables, or processed foods.
Climate-controlled cold chain logistics are also used for other commodities such as live plants, flowers, medicines, and even canvas paintings!
There are several advantages of cold storage spaces for the food and agriculture industry, and they play a critical role in the storage and logistics of most of the food items that are imported from abroad or produced in the country. Let’s take a look at exactly how a cold chain works:
From Farm to Processing
Almost every food product we eat goes through some sort of processing before reaching us. Cold chain solutions like refrigerated containers and trucks are generally used in transporting the food from the farms where they are grown to these processing warehouses. For instance, apples grown in orchards are transported to factories where they can be processed into apple jam and juice. All of this needs to be done in an environment with controlled temperature to prevent spoilage and maintain the quality of the raw materials.
Different Environments for Storing Different Types of Products
Not all cold storage solutions are the same, and this is because every product has a different requirement when it comes to cold temperatures. For example, potatoes require very different conditions compared to ice cream.
Cold storage facilities such as refrigerated warehouses, blast freezers, and cold stores are uniquely designed to create the conditions necessary to store specific items. Large cold storage facilities, however, are equipped to handle a variety of products.
Less Food Waste
Up to 40% of the food supply in the US gets wasted each year during its journey from the farm to American homes. Although this number is high, it would be much higher if it wasn’t for the temperature-controlled environment of cold storage.
Cold storage facilities, especially blast freezers, cool down the product in a way that protects them against bacterial growth that causes decaying. Billions of dollars worth of agricultural produce, meat, seafood, dairy items, and consumer packaged goods (CPGs) are stored in an extremely cold environment so as to extend their shelf life. By storing foods in a controlled-temperature environment, producers also prevent food-borne pathogens.
Curing or Maturing of Meat and Dairy Products
Meat and dairy products, like beef and cheese, need to be aged in a temperature-controlled setting so the product can last longer and taste better. Cheese manufacturers store and mature their products in cold temperatures for a period of time until they are ready to meet the customers’ demand. This preservation method of maturing or curing in cold storage is common practice for extending the shelf life of food items and ensuring their safety and quality don’t deteriorate.
From Storage to Retailers
Finally, the last step in the cold chain is the transportation from storage or a distribution center to supermarkets, grocery stores, health food stores, delicatessens, restaurants, and other retailers. It is a critical step and the product must arrive at its final destination in top quality. Cold storages located in strategic locations can help position food closer to the end consumer for faster delivery.
Types of Cold Storage Solutions
As we mentioned earlier, there are different types of cold storage solutions, designed to provide different cooler temperatures for different products. Here are some of the most common ones:
Blast Freezers
Blast freezers are used by companies that need to rapidly cool food and store it for a longer period before it reaches the end consumer.
Plant-Attached Cold Storage
These are warehouses attached to the production facilities. Manufacturers can transport their products via conveyor belts directly from point A to point B, keeping all operations in-house and on-site.
Public Cold Storage Warehouses
Many companies that use cold storage have varying needs based on the preferences of their end consumers and the nature of their products. Those who can’t use plant-attached cold storage resort to using public refrigerated warehousing or a custom cold storage facility from third-party logistics providers.
Benefits of Cold Storage
Cold storage is the most effective means for efficient bulk handling of perishable foods between production and marketing.
In addition to the food industry, sectors like cosmetics, medical, biotechnology, and pharmaceuticals heavily rely on the storage capacity and capability of cold chains. Here are some of the benefits of using cold chain logistics to store and transport your goods:
Temperature Control
From farm to food, temperature control allows you to provide the best quality products for your consumers. Food must be kept at certain temperatures throughout the cold chain in order to maintain the freshness and taste of the food. And different foods require a variety of temperatures to preserve that quality. With cold storage warehouses, you are able to control and monitor the temperature you require.
Extended Shelf-Life of Perishable Food Products
We have already established that cold storage is the process of storing perishable goods in super cold environments to increase the lifespan of products – and it can be done in a variety of ways.
Humidity is an important element and many refrigeration systems are capable of maintaining adequate temperature controls. This technology helps explain why seasonal fruits – which are only produced during certain months – are available to us throughout the year.
Cost-Effective
One of the biggest advantages of bulk cold storage is that it saves money for the consumer. Since cold storage keeps spoilage minimal, producers are not forced to increase prices. Plus, advanced blast freezers and other cold storage technologies of today use less energy, leading to further savings.
Frees Up Space
Managing wholesale products is not easy. It is even more challenging in the case of perishable goods. A retail store can’t keep all the perishables on-site as it would utilize too much space. And adding refrigeration systems of your own can be expensive.
Using a third-party cold storage facility is the obvious and more affordable solution. By storing all your goods in one place, you can consolidate your inventory and make it easier to keep track of your sales and purchases. Also, it’s far easier to regulate the temperature according to your needs inside a cold storage warehouse than in a retail store.
Transportation of Products
For industries that need their products to be stored and transported at low temperatures, cold chain logistics are a boon. Frozen foods, dairy products, poultry, etc., need to be transported from storage facilities to distribution centers and stores – and this can’t be done in an ambient temperature environment.
Even a seemingly small change in temperature can cause perishables to spoil and become unacceptable in the eyes of customers. The cold chain ensures that the product is kept in a safe and uncontaminated environment from the day it is produced/harvested to the day it reaches a retail store or restaurant. Safe transportation of perishables would be impossible without a cold chain.
The cold supply chain, including cold storage, has been a benefit to the food industry since the mid-19th century. It allows surplus food to be used in a way that would not have been possible otherwise. How else would producers of frozen foods and other perishables be able to distribute their goods across the world, spanning thousands of miles taking several days, without the risk of complete decay?
Dependable, Flexible, and Affordable Cold Storage for All Your Needs
At Vertical Cold Storage, our state-of-the-art warehouses come with a full management system, complete with web portals for customer ordering and live inventory tracking. Hundreds of manufacturers and distributors of perishable foods rely on our expertise, knowledge, and technology to provide them with complex cold chain solutions.
From blast freezing, analytics, and warehousing solutions that utilize data, to customized logistics and importing/exporting, we can ensure the safety and quality of your inventory, preventing spoilage and saving costs. We offer a multi-temperature storage network that can be used for a vast variety of inventory: frozen foods, baked goods, confectioneries, meat, seafood, fresh vegetables and fruits, and much more.
We handle products that need to be stored at temperatures from 55 degrees Fahrenheit to -20 degrees. Our experienced teams go the extra mile in making sure your products are maintained according to government regulations and your specifications.
Whether you deal with fresh or frozen food products, we can handle it all. Here’s what you can expect:
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24-hour temperature monitoring system
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Real-time inventory analysis
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Fully-automated Warehouse Management System (WMS)
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Standard Operating Procedures (SOP) utilized in all facilities
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Robust equipment and experienced and friendly staff
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Long and short-term storage
For any questions, please reach out to us via email at contactsales@verticalcold.com or send us a message online.