Automating a Cold-Storage Warehouse: Cold Constraints and Robotic Solutions

Automating a cold-storage warehouse poses a different equation than a standard warehouse: condensation, frost, lubricants that thicken, batteries that lose runtime, and operators facing real physical strain (warm-up breaks, cold-weather bonuses). Robotic solutions for sub-zero cold already exist, but not all are equal, and some temperature ranges still need to be confirmed before any project. This guide reviews the landscape sector by sector.

Automating a cold-storage warehouse: why cold changes everything for handling

The cold-chain sector accounts for around 8% of French warehousing revenue, with growth of 39.4% between 2017 and 2024 and roughly 700 facilities recorded (source: Arthur Loyd). Market leader STEF alone reports €4.44 billion in revenue and 242 platforms (source: STEF, 2023). A substantial market, but an environment that puts every piece of equipment to the test, human or robotic.

Condensation, frost and sealing: the enemy of sensors and mechanisms

Repeatedly moving between a temperate zone and a sub-zero cold room generates condensation, then frost, on metal surfaces, optics and connectors. For a mobile robot, this directly affects the LiDAR, cameras and navigation sensors, as well as the moving mechanisms (forks, wheels, actuators), which must stay sealed and free of freeze points.

Lubricants, batteries and materials: what sub-zero cold degrades

Below 0°C, standard lubricants thicken, plastics become brittle, and batteries — lithium ones especially — see their capacity drop and their charging slow down. Designing equipment for extreme cold calls for specific lubricants, suitable materials and battery thermal management: this is not a simple software option, it is dedicated hardware engineering.

Operators: physical strain, cold-weather bonuses and turnover

For forklift operators and order pickers, working at -25°C requires warm-up breaks, personal protective equipment and, under many collective agreements, a « cold-weather bonus » (sources: TLF-OAC, Cegedim Business Services). This is not an HR footnote: it is a direct driver of turnover and hiring difficulty for these roles, on top of an already high energy cost — electricity accounts for 41.6% of the cost of a cold-storage service (source: Made in FR, February 2025).

Automating in a cold environment: the robotic solutions that already exist

Contrary to popular belief, robots designed specifically for sub-zero cold do exist on the French market, provided you distinguish dedicated solutions from general-purpose AMRs.

iFollow, the French AMR designed for -25°C

French company iFollow advertises AMRs operating down to -25°C, for loads from 300 kg to 1.2 tonnes (source: ifollow.fr). It is today one of the few players to publicly document extreme-cold compatibility for an autonomous mobile robot, making it a reference point in the "cold-storage warehouse automation" space in France.

Alstef and automated storage in sub-zero cold

Alstef (formerly BA Systèmes) positions itself as a French leader in automated sub-zero pallet storage, with food-industry references including Candia, Yoplait, Bonduelle, Charal, Heineken and Nestlé Purina (source: alstefgroup.com). This is heavy automation, however — stacker cranes, conveyors — designed for large, stable volumes, not flexible mobile robots.

The general rule: most standard AMRs remain limited to positive-temperature cold

Outside these documented cases, most AMRs on the market are rated for an operating range of roughly 0°C to +40°C, so they are designed for positive-temperature cold or ambient conditions, not deep-freeze. Before any project in a sub-zero cold room, thermal compatibility must be checked robot by robot, on the manufacturer's data sheet, never assumed.

Automating a cold-storage warehouse: where does the autonomous pallet truck stand?

The robot is a 2,000 kg autonomous pallet truck, launched on August 18, 2026, whose official product sheet documents load capacity, LiDAR-SLAM navigation and battery runtime in detail, but does not state an operating temperature range. No public communication from the manufacturer confirms compatibility with sub-zero cold or deep-freeze conditions to date.

In concrete terms, this means we can neither confirm nor rule out that the autonomous pallet truck operates at -25°C: the information simply is not public. As a precaution, deployment in a sub-zero cold room should be considered unconfirmed until compatibility has been validated directly with Easy to Carry Robotics.

On the other hand, a large share of a cold-storage warehouse's flows remain in positive-temperature cold or temperate zones: receiving/shipping docks, staging areas before goods enter the cold room, transfers between an ambient warehouse and a positive-cold airlock (0/+4°C, fresh products). In these zones, the robot can be considered just as in any standard warehouse, subject to a site assessment. For any sub-zero or deep-freeze zone, the recommended approach is to request written confirmation of compatibility before committing to a project.

The benefits of automating handling in a cold-storage warehouse

Automating handling in a cold environment addresses more pronounced challenges than elsewhere, precisely because the physical strain and human cost are higher there.

Reduce human exposure to cold. Every mission handed to a robot is one the operator does not perform at -25°C — less exposure time, fewer warm-up breaks to organize, fewer cold-related work stoppages.

Address turnover and hiring difficulty. Positions in sub-zero cold rooms are structurally harder to fill and retain; automating the most repetitive and physically demanding tasks (pallet shuttling, dock-to-storage transfers) eases the pressure on these teams.

Limit door openings and wasted energy. Every crossing between zones at different temperatures costs energy; regular, optimized robotic missions can help limit unnecessary door openings, in a sector where energy already accounts for 30 to 40% of operating costs (source: Made in FR, Arthur Loyd).

Strengthen traceability. In cold-chain food operations, every robot mission is timestamped and logged: a useful support for HACCP traceability and quality audits, in addition to — not in place of — existing controls.

How to launch an automation project in a cold-storage warehouse

Step 1, Map your temperature zones. Precisely distinguish your ambient, positive-cold (0/+4°C) and sub-zero (-18°C and below) zones: robotic feasibility is not the same everywhere, and this breakdown will determine which solutions are viable.

Step 2, Check the data sheets, not the sales pitch. For any robot considered for sub-zero use, demand the operating temperature range documented by the manufacturer. If it is not public — as is currently the case for the robot — request written confirmation before making any commitment.

Step 3, Start with positive-cold or ambient zones. A dock-to-storage flow in positive cold or a temperate zone is a simpler, already-documented entry point for a general-purpose autonomous pallet truck, before considering an extension into sub-zero cold once compatibility is confirmed.

Step 4, Don't overlook the human and regulatory side. As with any autonomous mobile robot, the safety reference remains the EN ISO 3691-4 standard; the employer must train and authorize operators working nearby, and it is recommended to have the setup validated with your Carsat or the INRS before deployment.

FAQ

Can a handling robot operate in a sub-zero cold room?

It entirely depends on the model: some AMRs, such as those from French company iFollow, are designed to operate down to -25°C. But most standard AMRs are rated for 0°C to +40°C, meaning positive-temperature cold only. Always check the manufacturer's data sheet before any deep-freeze project, without assuming undocumented compatibility.

Does the robot work in a cold-storage warehouse?

Its compatibility with sub-zero cold is not publicly documented to date: the official product sheet does not specify a temperature range. Operation in the cold should therefore be neither confirmed nor ruled out. For any sub-zero cold room, written confirmation from Easy to Carry and the manufacturer is essential before committing to a project.

Why automate a cold-storage warehouse rather than a standard warehouse?

Because physical strain is greater there: warm-up breaks, cold-weather bonuses, high turnover and a significant energy cost (up to 41.6% of the cost of a cold-storage service). Automating pallet shuttles reduces human exposure to cold, limits energy-draining door openings and strengthens the timestamped traceability useful for HACCP audits.

Which players already offer robots for cold environments in France?

iFollow documents AMRs down to -25°C for 300 kg to 1.2 tonnes. Alstef (formerly BA Systèmes) is a French leader in heavy automated pallet storage for sub-zero cold, with well-known food-industry clients. For other robots, including the robot, sub-zero compatibility still needs to be checked directly with the manufacturer.

Do operators in a cold-storage warehouse need a cold-weather bonus?

Many collective bargaining agreements and company-level agreements provide for a cold-weather bonus for work in sub-zero rooms, in addition to warm-up breaks and personal protective equipment. Exact conditions vary by company and industry: check your collective agreement or contact your Carsat.

Related reading

• autonomous pallet truck: a complete overview of the autonomous pallet truck, every documented specification, including areas of uncertainty such as temperature.
• Autonomous pallet truck: the complete 2026 guide, understanding the technology before considering it for a cold environment.
• Forklift-operator shortage: 5 concrete solutions, turnover in sub-zero cold is just one variation of a wider problem.
• ROI of a pallet-truck robot: the calculation method, costing a project, energy and physical strain included.
• Automating a warehouse with no conveyors or construction work, the AMR path for your site's ambient and positive-cold zones.

Planning an automation project in a cold-storage warehouse? Before any commitment, always check the cold compatibility of the equipment you're considering: the robot's temperature range is not publicly documented to date. Discover the autonomous pallet truck or contact Easy to Carry to have the feasibility of your project confirmed, temperature zone by temperature zone.