ASRS Smart Cold Storage Automated Storage and Retrieval System (ASRS) is the pinnacle of modern cold chain technology, combining automated high-rise racking systems (25m to 40m) and computer-controlled Stacker Crane robotic systems. As a leading EPC general contractor for industrial refrigeration and air conditioning in Vietnam, Tan Long Refrigeration and Electrical Engineering is proud to have designed and constructed central industrial refrigeration systems for record-breaking national-scale ASRS cold storage projects such as... NECS cold storage (102,642 pallet positions) and AJ Total automated cold storage (30,700 pallets).
1. A breakthrough from ASRS high-rise automated cold storage.
In the context of industrial land prices in the areas cold chain logistics center With the increasing number of satellite warehouses (Long An, Binh Duong, Dong Nai, Bac Ninh, Hung Yen), the traditional low-rise cold storage model (only capable of holding 3-5 shelf levels) reveals many serious limitations. ASRS cold storage completely solves this problem:
- Increase storage capacity by 200% – 300%: Building heights ranging from 25m to over 35m, optimizing every square meter of floor space.
- Unmanned operation in extremely cold regions (-25°C): The entire process of lifting and loading pallets is performed by automated robotic cranes, completely eliminating health risks for workers working in cold environments.
- Lightning-fast import and export speeds: The robot moves at speeds of up to 150-200 m/minute, precisely locating each pallet barcode using WMS/WCS warehouse management software.
SCADA Central Monitoring and Control System ASRS AJ Total automated cold storage
2. Thermodynamic Challenges and Solutions for Tan Long's ASRS Refrigeration System
Designing a refrigeration system for an ASRS warehouse over 30m high is an extremely complex mechanical and electrical problem that very few contractors in Vietnam have the capacity to solve.
Thermal stratification
Hot air tends to rise to the ceiling while cold air sinks to the floor. Without proper calculations, the temperature at the top of the warehouse could reach -15°C while the bottom could be -25°C, causing damage to goods on the upper levels. Tan Long Solution: Using CFD airflow simulation software, we designed the layout of the high-level evaporators in combination with a Desratification Fans system to distribute temperature evenly throughout the warehouse within an error range of less than ±1.0°C.
High-capacity central NH3 refrigeration system
For cold storage facilities with a capacity of over 30,000 pallets, using NH3 (R717) refrigerant with forced-circulation pumping is a mandatory solution to optimize energy costs. The system utilizes a two-stage Mycom (Japan) or Mayekawa screw compressor unit, combined with a pressure vessel that meets stringent safety certifications.
The central NH3 compressor room operates the AJ Total automated cold storage facility constructed by Tan Long.
Solutions to prevent condensation and heat loss at dock entrances/exits.
Tan Long installs a high-speed T-Light automatic sliding thermal insulation door system combined with an anteroom/buffer zone that maintains a temperature of +5°C to +10°C, an air dehumidification drying system, and a dock seal that completely covers the container during loading and unloading.
3. Comparison of economic efficiency: ASRS cold storage vs. traditional cold storage
| Rating Index | Traditional Cold Storage | ASRS High-Rise Automatic Cold Storage |
|---|---|---|
| Land area required for 30,000 pallets | 18,000 m² – 22,000 m² | Only 6,000 m² – 7,500 m² is needed (Saving 65% of land) |
| Power consumption per pallet | 100% (Basic level) | Reduced by 35% – 45% (thanks to compact warehouse volume and casing). PIR cold storage panel high-class) |
| Labor costs for warehouse operations | A team of 30-50 forklift drivers and warehouse workers. | Only 4-6 technicians are needed to operate the machine room (Reduced 80%) |
| Inventory accuracy | 95% – 97% (location easily confused) | 99.99% (Automated real-time pallet barcode management) |
MYCOM high-capacity screw compressor system at NECS Long An super cold storage facility.
4. Proof of practical capabilities: 2 National ASRS mega-projects by Tan Long.
NECS Smart Cold Storage (Long An)
- Scale: 102,642 pallet positions (The largest cold storage facility in Southeast Asia).
- Height: The tall, high-rise cold storage building stands out.
- Tan Long Project: General contractor for central HVAC system, Mycom NH3 compressor, evaporator, automatic refrigerant supply system and SCADA.
AJ Total Automated Cold Storage (Ha Nam & Dong Nai)
- Scale: 30,700 pallet positions, automation technology from South Korea.
- Temperature: -25°C nationwide frozen food distribution.
- Tan Long Project: We provide and install complete compressor stations., PLC control cabinet, T-Light warehouse door.
Site Survey & Investment Project Planning for ASRS Cold Storage
Tan Long Refrigeration and Electrical Engineering accompanies investors and logistics corporations from the feasibility study (FS) stage, calculating energy COP, to the implementation of turnkey EPC projects.
ASRS Technology Commander: Engineer Nguyen Toan Thinh
Tan Long's Technical Director directly supervised the temperature stratification solution, the selection of the MYCOM NH3 compression unit, and the inverter energy-saving algorithm for the NECS project (102,642 pallets) and AJ Total Long Hau.
Is your business in need of a survey and investment estimate for an Automated Refrigeration System (ASRS)?
Tan Long provides comprehensive solutions: 3D layout design, CFD thermodynamic simulation, CAPEX/OPEX breakdown, and turnkey construction.
