Cold-Chain Multi-Client Warehouses Require Careful Attention to Detail

Proper handling and regulatory compliance for food and beverage is paramount throughout the cold chain, including within the warehouse. Interest in multi-client warehousing is growing as companies look to expand their footprint and move inventory closer to consumers.

Temperature compliance is paramount for both the quality of product and for food safety precautions. Penske Logistics has a team of subject matter experts leading our Food Safety Program to ensure compliance with the Food Safety Modernization Act as well as meeting third-party GFSI Food Safety Audits with high marks.

However, even smaller footprints within food-grade facilities require careful attention to detail. According to the Annual Third-Party Logistics Study, the cold chain requires a certain level of sophistication from both shippers and logistics providers, and several unique challenges within the cold chain require tracking and special designs.

Tracking and Tracing

Tracking is used in several areas, including the monitoring of temperatures as well as the lot control and expiration dates.

Penske utilizes temperature tracking in different zones throughout the warehouse. Most refrigerated facilities are multi-temperature, which include refrigerated, frozen and air conditioned or ambient temperature spaces.

Small sensor devices, some resembling hockey pucks, are used to monitor both high and low temperatures, supported by systems and personnel oversight to ensure compliance with customer temperature requirements. The same technology is also deployed in multi-temperature refrigerated trailers, enabling alerts to drivers if a refrigeration issue arises so they can promptly reach a service location for repairs.

Temperature tracking is as essential as inventory accuracy. When it comes to food and ensuring safety requirements are met and spoilage is mitigated, the warehouse management system WMS must be able to manage both. With systemic monitoring and controls, regulatory compliance of temperature monitoring for food safety controls effectively eliminates risk of temperature abuse or not storing foods at the proper temperature.

The warehouse management system tracks key product attributes, including lot control, expiration dates, and inventory rotation rules such as first-expired, first-out (FEFO) and first-in, first-out (FIFO). Maintaining high inventory accuracy is essential to ensuring an effective cold chain process. Customer-specific requirements are incorporated directly into the WMS rule set, with careful attention given to lot control and expiration dates, particularly when handling food and beverage products.

Building Design

Food and beverages must be stored in a food-grade building, which has several features not found in a standard warehouse. All ceiling lights must be shatterproof or have protection to catch any glass or debris if a bulb breaks. Plus, any warehouse area with temperatures below 32 degrees requires heat within the floor or else damage will occur.

The exclusion of pests, such as rodents and birds, is essential within the food and beverage industry. There must be 12-18 inches of gravel around the building in a food-grade warehouse to help prevent pests or rodents from entering the space. Additionally, nothing should be stored directly against the walls on the inside of the building, eliminating spaces that may be attractive to rodents.

Additionally, dock plates have brushes to minimize gaps. The dock door will have a dock shelter mounted on the concrete. When a truck backs in, it seals the truck to the opening, so no light comes through, to keep birds and rodents out.

A robust Food Safety Plan also must take into consideration all working operations to always maintain sanitary conditions of the facility. This includes the layout of traffic patterns for associates, adequate handwashing and associate facilities, adequate drainage, and designated storage areas for sanitation supplies and MHE equipment.

Penske maintains several food safety audit certifications, including the BRCGS Global Food Safety Standard. To get BRC certified, you have to follow standard operating procedures and do testing to make sure the building meets all of the requirements.

Cold Chain Growth

The Annual Third-Party Logistics Study found that opportunities exist within the cold chain, and 91% of shippers and 100% of 3PLs said they expect demand for cold chain capacity to increase over the next three years. Both shippers (70%) and 3PLs (52%) said COVID-19 accelerated their growth plans, increasing their need for more cold chain capacity.

As a result, 70% of shippers said they expect to grow their cold chain capabilities and talent over the next three years, while 50% said they plan to outsource more of their cold chain capabilities. About 90% of 3PLs said they plan to expand their cold chain capabilities and service offerings.

Penske’s Food Safety Program is designed to maintain all regulatory requirements, a Global Food Safety Initiative food safety audit program, along with any specific quality requirements to meet the needs of our customers. Penske actively participates in certifying leaders with the FSPCA Preventive Controls for Human Food as a tool to continuously cultivate and grow our Food Safety Culture. With Penske's dedicated Food Safety Leadership, our locations are monitored through a rigid internal auditing process for food safety that strives for continuous improvements to maintain a "best in class" food safety program.

To learn more about how Penske can assist with multiclient warehousing within the cold chain and food and beverage industries, contact us today.