Barpro Installations

Compact Cold Storage Efficiency with Mobile Racking – Kuhns Wholesalers, Brits

In January 2025, Barpro Storage SA completed a high-density mobile racking installation for Kuhns Wholesalers, a distribution business based in Brits, North West Province. The installation took place within a purpose-built freezer store and is a compelling example of how mobile racking can deliver exceptional storage capacity and operational efficiency, even in compact spaces. Project Overview Kuhns required a racking solution to maximise storage capacity within a relatively small freezer footprint, while still allowing safe, efficient product access. Working with internal building dimensions of 21m (L) x 10m (W) x 8.8m (H), Barpro designed a layout that combined two mobile racking banks with one static row, optimising both storage density and access. Initially designed for 3 pallets in the height, then increased to 4 pallets in the height allowing for a 25% increase in storage capacity. The result: an impressive 312 pallet positions, each designed to accommodate 1200mm x 1000mm x 1800mm pallets with a load capacity of up to 1200 kg per pallet. Integrated Safety & Functionality Features This project showcased more than just effective use of space—it demonstrates Barpro’s commitment to safety, innovation, and reliability in every installation: Wooden Bumpers (Barpro Exclusive)As part of our standard optional extras, Barpro introduced wooden bumpers, mounted on the Front Guide wheel units. Bumpers provide crucial protection to the mobile base wheel units, shielding them from accidental forklift impact and long-term wear. This small addition significantly prolongs the life of a mobile system—especially in freezer environments where driver fatigue and reduced visibility can lead to accidental impacts. Photoelectric Safety SensorsTo ensure operator and product safety, Barpro designed heavy duty photoelectric safety systems to suit South African market conditions. These sensors immediately halt all moving bases if any foreign object, pallet, or person enters the aisle during operation—providing a reliable fail-safe against accidents. Pallet Support Beams for Inferior Pallet HandlingGiven the variability in pallet quality across cold storage operations, Barpro supplied pallet support beams throughout the system. These beams provide added support one per pallet position, helping to: Reduce the risk of pallet deflection or collapse, Improve pallet placement consistency, Enable the system to handle lower-grade or damaged pallets that might otherwise pose a safety or storage risk. Individually Controlled Mobile BasesThe mobile bases were equipped with individual control electric drives, allowing operators to selectively open or close aisles based on operational needs. Individual control systems are more cost effective on smaller systems. Collaboration & Local Manufacturing This project was planned and executed in conjunction with refrigeration specialists, civil engineers, and insulated panel suppliers to ensure a smooth installation and integration within the overall cold store construction timeline. Barpro sourced all mobile bases and racking components locally. This enabled faster production times and long-term serviceability. Conclusion: Big Impact in a Small Footprint The Kuhns Wholesalers project demonstrates that mobile racking is not limited to large warehouse operations. With appropriate design, strategic collaboration, and the right combination of safety and support features, mobile systems can unlock value in even the most space-constrained environments. By implementing this solution, Kuhns has doubled their storage capacity over what was achievable through static racking, improved inventory handling , Improved product access, and created a safer, more reliable environment for both staff and stock—without having to expand their building footprint.

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Eskort’s processing plant upgrade       

Abstract of article by Cold Link Africa : Eskort’s pig meat processing plant upgrade drive effiencies Contributors to the main article : Eamonn Ryan (Cold link) with technical input from Stephen Frewen, refrigeration design engineer: AMC Engineers, Gert van Rooyen, lead applications engineer: HC Group, Robert Kershaw of Barpro Storage , and the team at Eskort. Eskort, South Africa’s leading pork manufacturer, has expanded its Gauteng production capacity by 50% with a factory extension incorporating a high-tech refrigeration system officially launched in mid-February. The expansion aimed to increase production to meet retail needs and maintain cold chain integrity. The development includes a high-tech refrigeration system, multi-level picking mezzanine floor systems, and cutting-edge refrigeration design by AMC Engineers. The expansion also features solutions by Barpro Storage that optimizes picking efficiency while minimizing time and resource wastage. Barpro Storage was one of the product suppliers in a team of consulting engineers & contractors managed by SCIP Engineering Group. OBJECTIVE The core objective of the factory extension was to create efficiencies and includes the addition of carcass chillers. The chilled and frozen warehouses now have multi-level picking mezzanine floor systems. These system maximises vertical space by including mezzanine floors with mobile racking that creates additional levels for storage and picking, and it allowed Eskort to handle high volume of orders quickly and efficiently. 1: Eskort factory staff – Source : Eskort The owners of the processing plant set their sights on having the most energy and operationally efficient plant possible for their expanded pork production. The need stemmed from a desire in increase capacity from the previous 6 000 pigs a week to 9 000. The 10 000m² development in Heidelberg – the small town where the company has produced world-class pork products for 70 years – will allow Eskort to increase production to meet retail needs. With the facility processing approximately 5.5 million kilograms of meat monthly, maintaining the cold chain integrity is paramount. The enlarged factory is equipped with the largest continuous box freezer in Africa, capable of freezing 120 000kg of products to -18°C every 24 hours. Boxes move on a conveyor belt through the freezing chamber where the air is kept at -31°C – a temperature that occurs naturally only in polar regions. The chilled and frozen warehouses now have multi-level picking mezzanine floor systems, the first of their kind in the food industry in South Africa. These systems maximise vertical space by including mezzanine floors with mobile racking that create additional levels for storage and picking, and they allow Eskort to handle a high volume of orders quickly and efficiently. Barpro devised solutions that optimised picking efficiency while minimising time and resource wastage. One unique innovation for the South African market was the maximising of vertical space by installing a picking mezzanine level. “These elevated platforms allow for efficient product retrieval, optimising floor space and streamlining operations. Each SKU has a designated pallet position, enhancing organisation and productivity,” says Lӧtter.    Willie Lӧtter – General Manager of Eskort He describes this as being revolutionary within the South African meat industry, underscoring its novelty and effectiveness. “The concept originated during the planning stages, with collaboration between Eskort and a company specialising in rack systems. Upon identifying the concept’s viability and success in European facilities, including a firsthand observation in Ireland, Eskort proceeded with its implementation.”    Follow the link to read the original article with detailed information :   https://coldlinkafrica.co.za/eskorts-pig-meat-processing-plant-upgrade-drives-efficiencies/

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Saysons Cold Storage, Phillipi: CASE STUDY

Barpro Storage SA (PTY) Ltd has increased Saysons Cold Storage’s, capacity with an additional 5103 pallet positions through the installation of mobile racking. Barpro Storage SA was appointed by Saysons Cold Storage, in 2002 and then again in 2009 to supply, deliver & install mobile racking systems to assist them in achieving their desired storage capacities. The newest mobile racking system is designed for frozen pallets with a height of 2000 mm, gross weight of 1200KG and 6 pallets high. Barpro was involved in the project from the early design and conceptualisation stages as the site had planning restrictions. Working with the architects allowed Barpro to design a layout which maximized storage capacity. The new facility has been established adjacent to their original store. Barpro was able to achieve 3.1 pallets per m2 of the freezer area, one of the  highest yet achieved. Saysons Cold Storage initially considered an oxygen depletion system for their fire safety requirements, however in the end chose to pursue a foam system instead. The floor was laid using rail from Barpro’s local stock together with bases and electrics manufactured locally. Barpro was able to complete the project without delaying the commissioning of the store. Additionally, Barpro added wooden bumpers, to protect the mobile bases & their control panels as well as pallet supports to assist in the placing and storage of pallets on the higher levels. Using mobile racking, Barpro was able to achieve a total storage capacity of 5103 pallet positions, 4480 positions situated in the mobile racking and the remaining 623 pallet positions situated within Static racking placed on either side of the mobile bases. With the use of Mobile and Static Racking Barpro has maximized the volume utilization of the cold store, while conscious of the clients’ requirements for throughput and pallet accessibility. The project was completed in early 2024, adding value and much needed space to Sayson’s expanding business operations.

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