Reimagining Warehouse Flow: Integrated Chilled–Ambient Storage at Derry Group Ireland
Maximising throughput, safety and space across connected chilled and ambient storage zones.
Key Figures at a glance:
| Location | Northern Ireland |
| Operational Time | 12 hours per day, 5 days per week (inbound 12 hours per day) |
| Throughput IN | 40 pallets per hour |
| Throughput OUT | 40 pallets out per hour |
| Taxis | 6 Moffett Automation Taxi pallet shuttles |
| Building Height | 16 metres |
| VTUs | 2 Moffett Automation VTUs |
| Inbound Locations | 2 |
| Outbound Locations | 2 |
| Special features | Dual connected chambers and integrated cooler platforms |
Project Overview
Derry Group Ireland is one of Ireland’s leading chilled and frozen food distributors, operating from Craigavon, County Armagh and serving customers across the island of Ireland. As demand increased, the business faced a major constraint: the site was landlocked, with no practical option to expand its warehouse footprint.
Moffett Automation partnered with Derry Group Ireland to design and implement an automated pallet storage system that maximised the potential of a new extension. The system was developed to increase pallet capacity, improve throughput, support movement between chilled and ambient storage zones, and create a scalable platform for future growth.
Project objectives:
- Enable seamless pallet movement across connected chilled and ambient storage zones
- Achieve over 5,000 pallet locations within the available footprint
- Improve throughput while reducing forklift dependency
- Integrate with Derry Group Ireland’s WMS for accurate inventory control
- Create a scalable system that can support future operational growth
Challenges Presented
Connecting Chilled and Ambient Storage Within a Landlocked Site
Derry Group Ireland’s primary challenge was space. The business needed to grow storage capacity and throughput but had no practical option to expand its site footprint. Manual material movement, limited space and rising demand created pressure on warehouse flow, safety and fulfilment performance.
The solution needed to maximise every available cubic metre, connect different storage zones and reduce reliance on forklifts in infeed and outfeed areas. It also needed to integrate with Derry Group Ireland’s Warehouse Management System to support accurate inventory control, real-time visibility and adaptable pallet movement.
Storage Transformed
Automated Chilled and Ambient Pallet Storage
Moffett Automation delivered an automated pallet storage system designed around Derry Group Ireland’s landlocked site, new extension and connected chilled–ambient storage requirements. The system combines automated pallet shuttles, vertical transfer, conveyor integration, WMS connectivity and safety infrastructure to increase capacity and improve material flow.
Moffett Automation Taxi pallet shuttles
6 Moffett Automation Taxi pallet shuttles were deployed to move pallets efficiently across the warehouse’s operational zones.
Moffett Automation Conveyor
The conveyor system was integrated with the warehouse infrastructure to support controlled pallet movement between infeed, outfeed and storage areas.
Moffett Automation VTU
2 Moffett Automation VTUs were introduced to support vertical pallet movement and improve use of available building height.
Moffett Automation WCS
Moffett Automation implemented warehouse control software to manage pallet storage, traffic control and route scheduling. The software was fully integrated with Derry Group Ireland’s existing WMS to support real-time inventory visibility and efficient pallet movement during peak periods.
Safety measures
The project included fencing, light curtains and controlled access measures to support safe interaction between people, equipment and automated pallet movement.
Technical online support
Moffett Automation provides 24/7 remote technical support from its in-house team to help maintain system availability and respond quickly to operational issues.
Local mechanical support
The Moffett Automation system is supported by a local service partner providing preventative maintenance and rapid 24-hour on-site response when required.
Project Results
Faster order turnaround, improved fulfilment accuracy, and greater product availability have strengthened Derry Group Ireland's market competitiveness.
One of the most impactful outcomes was the dramatic increase in storage density.
Derry Group Ireland’s new extension, equipped with the Moffett Automation system, achieved over 5,000 pallet locations, maximising every available cubic metre despite being landlocked. This optimisation not only met their growing storage needs but also ensured the system remained scalable and adaptable for future demands.
The automated transfer operations, powered by strategically positioned taxi-sized transfer gaps between chambers and integrated cooler platforms, greatly enhanced material flow and throughput across both ambient and chilled storage zones. This resulted in faster, more accurate processing, reduced lead times, and improved delivery performance.
By integrating seamlessly with Derry Group Ireland’s Warehouse Management System (WMS), the solution provides real-time inventory tracking and enhanced supply chain visibility, enabling better decision-making and a more cohesive approach to operations.
Safety was another major area of improvement. Eliminating the need for forklifts in all infeed and outfeed stations reduced congestion, minimised operational risks, and created a safer environment for warehouse personnel. The system’s energy-efficient design also optimises power usage during idle periods, lowering operational costs and supporting sustainability goals.
Feedback from Derry Group Ireland has been overwhelmingly positive. The system’s adaptability and built-in redundancy ensure uninterrupted operations and future-proof their intralogistics. By transforming their warehouse with Moffett Automation’s solution, Derry Group Ireland is now positioned to meet growing demand and drive continued growth.
