Sustainability and Innovation
Sustainability and innovation are not competing priorities; they are complementary forces that drive every aspect of our work. A standout example of this synergy can be found in a customer installation, Derry Group Ireland faced growing operational challenges due to being landlocked and unable to expand their footprint. With these constraints in mind, they partnered with Moffett Automation to design and implement a fully automated intralogistics solution that would maximize the potential of their new extension.
Both before and after automation, operations ran under the same energy envelope, allowing a clear comparison of efficiency and performance. The results were transformative. Our Moffett Automation system enabled over 5,000 pallet locations, dramatically increasing storage density and throughput without any additional energy demand. By replacing forklifts with automated transfers and optimising every cubic metre through vertical storage and intelligent control, energy consumption per stored pallet was significantly reduced. The outcome was a safer, smarter, and more sustainable warehouse – one that delivers faster order turnaround, improved accuracy, and measurable energy savings, proving that innovation and sustainability can move in perfect alignment.
Maximising Density, Minimising Energy
Higher pallet density means that more goods can be stored within the same physical and energy footprint, which translates directly into lower costs per unit stored and a smaller carbon footprint per pallet. This enhanced density reduces the overall square footage needed for warehousing operations, which in turn minimizes energy usage for lighting, cooling, and maintenance. In cold storage, where energy consumption is a major operating cost, such improvements are not just beneficial, they are transformative.
How Automation Cuts Energy Waste in Cold Storage
The sustainability advantages of our system extend well beyond storage density. Cold storage facilities, by their very nature, are energy-intensive environments. One often-overlooked factor is lighting, which can account for up to 30% of the energy used in refrigerated warehouses. Our system is designed to operate entirely without lighting in automated zones, as there is no human presence required. This eliminates the need for lighting altogether, resulting in substantial energy savings overtime. Facilities no longer need to keep lights on 24/7 simply to accommodate manual operations, our solution enables complete darkness without compromising performance or safety.
Additionally, we have addressed thermal inefficiencies commonly found in cold storage logistics. Our system incorporates rapid envelope or interlock doors that only open to the precise dimensions of the pallet being transferred. This prevents unnecessary heat exchange between temperature zones, significantly reducing cold air loss during operations. Over time, this results in less strain on refrigeration units, prolonging equipment life and reducing energy costs.
Lightweight Design, Intelligent Routing: Maximising Efficiency in Every Move
Another cornerstone of our sustainable design is the technology powering our movement systems. Our lightweight, 4-Directional Taxi shuttles weigh less than 350kg each and are engineered for energy efficiency. These shuttles consume less power per movement and are capable of maneuvering pallets in any direction, which reduces the number of movements needed and thus lowers energy usage. When idle, these shuttles do not simply wait in a fixed position. Instead, our Eco Traffic Intelligence system automatically routes them to the nearest available charging station. This system minimizes unnecessary travel, avoids traffic deadlocks, and ensures that every shuttle is either actively performing a task or charging in the most efficient location possible. By managing shuttle traffic intelligently, we reduce wear and tear on equipment, extend the operational lifespan of our systems, and conserve energy throughout the workday.
