Playing Tetris at Zero Degrees: Optimizing Atlantic Foods’ Cold Storage

The Situation

Atlantic Food Distributors is the real deal—an independent, family-owned supplier operating out of North Canton, Ohio. They have a massive 156,000-square-foot facility, and they needed to squeeze every possible inch of utility out of it. The challenge wasn’t just size; it was complexity. We needed to fit over 5,200 pallet positions into a layout that spans multiple temperature zones, from ambient dry storage to deep freeze.

The Work

We honestly love this part of the job. It’s basically industrial Tetris—figuring out how to get maximum density while ensuring the forklifts don’t end up in a gridlock. We analyzed their product mix and deployed a heavy-duty combo of Selective Pallet Racking for access, along with Carton Flow and Pushback Racking for the high-density SKU lanes.

The system looks sharp, too. We installed green uprights with red beams, which gives great visibility for the operators working in the warehouse. We set the 42-inch deep uprights using a mix of 12, 13, and 14-gauge steel to handle the specific weight loads of their inventory.

We don’t mess around with stability. The crew anchored every column using Hilti Kwik Bolt 3 anchors (1/2″ x 3 3/4″), torquing the base plates to a strict 40 foot-pounds. To protect that steel from the inevitable bumps and bruises of a busy dock, we bolted down 12-inch and 18-inch deflectors at the row ends. In the picking zones, we used poly wheel beds on the Carton Flow levels to keep the boxes sliding forward for easy access.

The Specs

• Client: Atlantic Food Distributors
• Location: North Canton, Ohio
• Facility Size: 156,000 Square Feet
• Capacity: 5,200+ Pallet Positions
• Rack Types: Selective, Carton Flow, Pushback
• Anchors: Hilti Kwik Bolt 3 (1/2″ x 3 3/4″)
• Torque Spec: 40 Foot-Pounds
• Safety: 12″ and 18″ Row End Deflectors

The Outcome

We handed over a rock-solid system ready for immediate stocking. The new Carton Flow and Pushback lanes mean Atlantic can rotate stock faster than before, keeping their logistics smooth. It was a solid win to partner with a local Ohio crew and help them gear up for their next growth spurt.