Raising the Bar for Cold Chain Logistics: Refrigafreighters Ruakura
At Ulti Group, we deliver smart, high-performance access solutions that conserve energy, increase efficiency, and protect products. The newly completed Refrigafreighters Cold Freight Depot in Ruakura exemplifies these values in action.
Strategically located in Hamilton’s fast-developing Ruakura Superhub, this state-of-the-art facility is engineered to maintain strict cold chain integrity while enabling fast, safe, and seamless logistics operations. Ulti Group partnered with Calder Stewart and Refrigafreighters to deliver a complete end-to-end access and docking solution.
Product Overview
The Refrigafreighters depot showcases the breadth and depth of Ulti Group’s industrial entrance systems.
- Environmental Load Area
A temperature-buffering zone positioned between dock doors and freezers, the ELA protects frozen products from sudden temperature and moisture changes. This prevents ice build-up and reduces the risk of packaging or product damage due to condensation or snow inside the freezer.
- Pressure Relief Ports
Mounted high on freezer walls, these ports regulate internal air pressure to prevent suction damage to doors. Ulti Group installed high-quality models with heat tracing to prevent freezing of the relief flaps – ensuring long-term functionality and safety.
- Docking Systems
Each dock features:
– Ulti Dock Levellers with under-leveller seals for complete four-sided sealing.
– Ulti Thermo80 Insulated Sectional Doors, 80mm thick with full thermal breaks.
– Ulti Endura Dock Shelters, soft-sided and impactable, for effective truck-to-building seals in chilled environments.
– Ulti Dock Bumpers, upgraded to steel-faced for durability, protecting structures from truck impact.
Each dock is a sealed, smooth transition system ensuring forklifts can move efficiently without jarring or structural damage, while maintaining the thermal barrier at all times.
- Traffic and Safety Systems
The depot features:
– Exterior Light Communication Systems for safe loading signal management.
– Master Control Panels that coordinate leveller activation, door operation, and light cues – enhancing workflow clarity and minimising loading errors.
🎥 Video Showcase Coming Soon
We’ll soon be releasing a full project spotlight video of the Refrigafreighters Ruakura depot – highlighting the Environmental Load Area, dock shelters, light communication systems, and much more. Stay tuned for a behind the scenes look at how each system performs in real time.
Built for Performance and Protection
From the smallest seal to the largest dock every Ulti Group component installed at Ruakura was selected with care – designed to support uninterrupted cold chain logistics, operator safety, and long-term durability. This facility stands as a shining example of what’s possible when performance, precision, and partnership come together.
If you’re building, expanding, or upgrading a logistics facility, Ulti Group can help you deliver results – no sweat.
FAQs
1. What was Ulti Group’s role in the Refrigafreighters Ruakura project?
Ulti Group supplied, installed, and commissioned the complete dock and door systems for this facility, including high-performance freezer doors, sealed dock levellers, thermal barriers, light communication systems, and safety features. The project was delivered in collaboration with Calder Stewart and Refrigafreighters to achieve superior energy efficiency and product protection across the cold chain.
2. What is an Environmental Load Area (ELA), and why is it important?
An ELA is a transitional space between ambient or chilled zones (2-10°C) and freezer environments (-20°C). It buffers temperature differences, allowing refrigeration systems to extract moisture from the air before it enters the freezer. This prevents ice build-up, snowing, and product damage, making it a critical component for cold chain distribution centres.
3. How does Ulti dock levellers maintain cold chain integrity?
Ulti Dock Levellers feature:
- Side and under-leveller seals to stop warm and moist air infiltration
- Smooth transitions for forklifts to reduce impact loading
- Integrated control consoles for safety and efficiency during loading
These features ensure thermal protection and structural longevity at each loading bay.
4. What is a sealed dock system, and how does it differ from traditional setups?
A sealed dock system includes:
- A fully insulated sectional door
- A pit-mounted dock leveller with edge and underside sealing
- A dock shelter sealing the truck perimeter
This prevents uncontrolled airflow between ambient and chilled zones. Traditional docks often allow gaps around trucks or levellers, which can cause condensation and energy loss. A sealed dock maintains thermal integrity while streamlining operations.
5. Can Ulti Group deliver a similar solution for our facility?
Absolutely! Whether you’re developing a new distribution centre or upgrading an existing site, Ulti Group can design and deliver a custom access solution tailored to your operational needs and compliance requirements – especially in cold storage, logistics, food production, and retail environments across New Zealand and Australia.
Get in contact with us today to see how we can help your facility protect what matters to you.
