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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