--- title: 6 tips to think lean in cold warehouses description: Here are some material handling solutions to common challenges in cold store such as space, cost, battery capacity and condensation. image: https://blog.toyota-forklifts.eu/hubfs/Imported%20sitepage%20images/26874_768x400_toyota%20mh.jpg --- [Go to toyota-forklifts.eu](https://toyota-forklifts.eu) [Blog](https://blog.toyota-forklifts.eu) SUBSCRIBE TO THE BLOG [![Toyota](https://cdn2.hubspot.net/hubfs/5544767/HubSpot%20onboarding/Images/Logo/logo.png)](https://blog.toyota-forklifts.eu) [All](https://blog.toyota-forklifts.eu) [Lean](https://blog.toyota-forklifts.eu/tag/lean) [Connectivity](https://blog.toyota-forklifts.eu/tag/connectivity) [Automation](https://blog.toyota-forklifts.eu/tag/automation) [Products & Solutions](https://blog.toyota-forklifts.eu/tag/products-solutions) [Energy](https://blog.toyota-forklifts.eu/tag/energy) [All articles](https://blog.toyota-forklifts.eu) [Products & Solutions](https://blog.toyota-forklifts.eu/tag/products-solutions) 6 tips to think lean in cold warehouses # 6 tips to think lean in cold warehouses ![Picture of Roger Johansson](https://blog.toyota-forklifts.eu/hubfs/Roger%20Johansson%20picture_2.jpg) #### Roger Johansson [![Share on Facebook](https://static.hubspot.com/final/img/common/icons/social/facebook-24x24.png)](http://www.facebook.com/share.php?u=https%3A%2F%2Fblog.toyota-forklifts.eu%2F6-tips-to-think-lean-in-cold-warehouses%3Futm_medium%3Dsocial%26utm_source%3Dfacebook) [![Share on LinkedIn](https://static.hubspot.com/final/img/common/icons/social/linkedin-24x24.png)](http://www.linkedin.com/shareArticle?mini=true&url=https%3A%2F%2Fblog.toyota-forklifts.eu%2F6-tips-to-think-lean-in-cold-warehouses%3Futm_medium%3Dsocial%26utm_source%3Dlinkedin) 3 minutes to read ###### [Reach trucks](https://blog.toyota-forklifts.eu/tag/reach-trucks) , [cold store](https://blog.toyota-forklifts.eu/tag/cold-store) One of the main challenges in cold environments is to maintain the right temperature for products, frozen or chilled, while keeping workers and equipment warm enough to keep efficiency high. To maximise space utilisation and reduce downtime, whilst retaining flexibility, you need to have access to the right equipment and lean solutions to keep operating costs under control. To improve these and other common challenges such as condensation and battery issues, here are some tips to optimise operations in cold warehouses. ## 1. Use the right equipment Reliable, fast, manoeuvrable material handling equipment will support a smooth goods flow to ensure fresh goods don’t spoil. [Cold store operations](https://toyota-forklifts.eu/solutions/your-sector/temperature-controlled-environments/) are one of the toughest material handling challenges, as sub-zero temperatures may affect your forklifts. Therefore, to minimise breakdowns and repair costs, dedicated cold store trucks with specialised options (such as cold store oil, stainless steel axles, etc) are highly recommended. In addition, with a [pre-operational check](https://toyota-forklifts.eu/solutions/i_site-fleet-management/), workers can make sure the equipment is ready to do the job without wasting any precious time in the cold. ![Toyota reach trucks for coldstore](https://blog.toyota-forklifts.eu/hs-fs/hubfs/Imported%20sitepage%20images/26874_768x400_toyota%20mh.jpg?width=864&name=26874_768x400_toyota%20mh.jpg) ## 2. Fill the cube ## ![Toyota Radioshuttle for high-density storage](https://blog.toyota-forklifts.eu/hs-fs/hubfs/Imported%20sitepage%20images/22235_768x400_toyota%20mh.jpg?width=428&name=22235_768x400_toyota%20mh.jpg) Space is costly in cold stores. Therefore, it is recommended to optimise your warehouse space utilisation. You can do this by choosing storage options that use your warehouse volume as efficiently as possible. For example, [automated shuttles](https://toyota-forklifts.eu/automated-solutions/semi-automated-shuttles/)maximise the use of space whilst keeping throughput high and minimising the number of workers necessary in the cold store. ## 3. Look into Lithium-ion battery technology Did you know [Lithium-ion batteries](https://toyota-forklifts.eu/solutions/energy-solutions/lithium-ion-battery-solutions-from-toyota/) lose little to no battery performance within the cold store and have an energy efficiency that is up to 30% higher than lead-acid? This allows for a longer running time, opportunity charging, and in combination with the ability to charge within the cold store thanks to the battery heater solution, the trucks are able to perform continuously throughout the shift. The chargers need to be placed in a warmer area within or outside the cold store. ## 4. Make sure workers are comfortable Besides proper clothing, workers’ productivity will benefit from intuitive and reliable equipment that keeps them warm in the cold. For example, equipping [reach trucks with a heated cabin](https://toyota-forklifts.eu/premium-trucks/reach-trucks/new-bt-reflex/) can contribute to your employees’ health and safety. The extra cost related to heated cabins has a quick payback time since productivity stays high thanks to staff being comfortable during their shift and taking less work breaks (these are common practice in cold environments and typically represent a 10%–15% loss in productivity).![Toyota reach truck with heated coldstore cabin](https://blog.toyota-forklifts.eu/hs-fs/hubfs/Imported%20sitepage%20images/26814_768x400_toyota%20mh.jpg?width=860&name=26814_768x400_toyota%20mh.jpg) ## 5. Consider automating repetitive tasks A simple way to reduce the number of workers in the cold areas is to automate certain processes. Introducing [automated warehouse trucks](https://toyota-forklifts.eu/automated-solutions/automated-warehouse-trucks/)for automated pallet transport or storage can be phased in step by step. Employees can then take up alternative tasks where they are not exposed to the harsh working conditions. ## 6. Keep up with service Working in cold and wet conditions puts a lot of strain on your machines. Access to skilled [service](https://toyota-forklifts.eu/toyota-service/)technicians and genuine parts is key to make your operation running smoothly 24/7. With our [smart trucks](https://toyota-forklifts.eu/solutions/i_site-fleet-management/) we’re able to support you, using data provided by telematics to improve your forklift service. We always recommend you to request a service plan, especially when working with forklifts in challenging conditions such as cold store. Toyota Material Handling has a long history and experience working in low-temperature operations, offering as standard a full range of vehicles for chilled operations as well as dedicated cold store solutions. By taking a lean approach we can ensure a continuous flow and minimum waste in your operation. [![READ MORE ABOUT COLD STORE SOLUTIONS](https://no-cache.hubspot.com/cta/default/2875940/3e72dda9-f2af-40bc-890d-e9e04710f7b0.png)](https://cta-redirect.hubspot.com/cta/redirect/2875940/3e72dda9-f2af-40bc-890d-e9e04710f7b0) ![Picture of Roger Johansson](https://blog.toyota-forklifts.eu/hubfs/Roger%20Johansson%20picture_2.jpg) #### Roger Johansson Roger is product manager in charge of Toyota Reflex Reach trucks at Toyota Material Handling Europe. With over 20 years of experience, he has spent the last 10 years working with automated material handling systems. [Roger Johansson](https://blog.toyota-forklifts.eu/author/roger-johansson) ### Stay informed of the latest developments ## Related articles [![](https://blog.toyota-forklifts.eu/hs-fs/hubfs/DSC_0883.jpg?width=191&name=DSC_0883.jpg)](https://blog.toyota-forklifts.eu/digitalisation-unlocking-supply-chain-resilience-insights-from-industry-leaders) ## [Digitalisation unlocking supply chain resilience: insights ...](https://blog.toyota-forklifts.eu/digitalisation-unlocking-supply-chain-resilience-insights-from-industry-leaders) [![](https://blog.toyota-forklifts.eu/hs-fs/hubfs/Service%20technician%20training%20-%20forks.jpg?width=191&name=Service%20technician%20training%20-%20forks.jpg)](https://blog.toyota-forklifts.eu/why-keeping-your-field-service-technicians-healthy-and-productive-is-crucial) ## [Why keeping your field service technicians healthy and ...](https://blog.toyota-forklifts.eu/why-keeping-your-field-service-technicians-healthy-and-productive-is-crucial) [![](https://blog.toyota-forklifts.eu/hs-fs/hubfs/DSC_1327-Enhanced-NR.jpg?width=191&name=DSC_1327-Enhanced-NR.jpg)](https://blog.toyota-forklifts.eu/ai-in-logistics-from-hype-to-impact-insights-from-industry-leaders) ## [AI in logistics, from hype to high impact: insights from ...](https://blog.toyota-forklifts.eu/ai-in-logistics-from-hype-to-impact-insights-from-industry-leaders) ### Popular posts ## About this blog Inspired by TPS and Toyota Way, Toyota Material Handling brings you the latest updates on logistics and material handling. 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