State-Of-The-Art Systems For Countdown’s New Auckland Distribution Facility
The Challenge
Countdown needed a state-of-the-art facility to centralise their fresh product operations for the North Island and keep their fresh products cool and safe.
The Solution
Ulti Group designed and installed 21 fully interlocked dock loading systems to ensure their products are kept fresh and cool from storage through to transport, as well as a range of other specialist doors systems including Ulti Rolls, Ulti Spirals, and more, all with additional lighting systems for enhanced safety.
The Result
The new distribution centre was completed in October 2022, achieving a Green Star 4 rating for design and providing Countdown the capacity to distribute 350,000 crates of fresh produce a week to its 150 North Island stores.
With over 180 stores across the country, Countdown is one of New Zealand’s largest supermarket brands. In 2022, they opened a new, state-of-the-art temperature-controlled fresh produce distribution centre in Wiri, Auckland, to centralise their fresh product operations in the region. Built to handle 350,000 crates of fresh produce at one time and operate 24/7, it’s a high-tech facility that
plays an integral role in the full cool chain required to get fresh produce from farm to store in prime condition.
The building is also linked to the adjacent Hilton Foods warehouse to the West via an air bridge. An automated conveyor within the air bridge delivers packaged meat products to the distribution centre, allowing trucks to be loaded with both veggies, fruit and meat at the same time – reducing carbon emissions and providing efficiencies of scale.
Ulti Group worked closely with Countdown and its contractors to design and install specialist door and dock loading systems that would efficiently maintain temperatures across the facility and provide high levels of safety and energy savings to meet Countdown’s requirements. The new facility included 21 fully interlocked dock loading systems, including sectional dock doors, vertical dock levellers, inflatable dock seals, global wheel locks, sliding dock bumpers, and combined dock commander operation panels, enabling Countdown to quickly and efficiently distribute their fresh produce. In addition, we installed 40 specialist doors including Ulti Rolls, Ulti Spirals and Roller Shutter Doors throughout the site, all with virtual vision light systems for enhanced safety. Also included were 42 hinged chiller doors and an acoustic sliding door.
The new distribution centre was completed in October 2022 and achieved a Green Star 4 rating for design. Countdown was very pleased with the outcome of the project and the quality and safety features of Ulti Group’s products and services.
“Ulti Group was great to work with. I’ve worked at a lot of big manufacturing plants in the past and I’d 100% use them again for future projects.”
– James Robson | Countdown – Primary Connect
Ulti Group is a trusted partner to Countdown providing full-service backup to all their products, long-term warranties, and peace of mind to know that they are in safe hands. We are proud to partner with cutting-edge companies in New Zealand, such as Countdown to complement efficient and effective operations with innovative door and dock loading systems.
If you want to learn more about how Ulti Group can help your business achieve your goals, reach out to us on 0800 807 753 for a free consultation.
