Costa Group
Overview
Costa Group is Australia's largest horticultural company and a major supplier of produce to food retailers, with an estimated market share of over 15%. As Australia's leading grower, packer and marketer of fresh fruit and vegetables, Costa supplies quality fruits and vegetables to all the major Australian supermarket chains as well as independent grocers and food industry stakeholders.
With multiple facilities across Australia handling diverse agricultural products including avocados, bananas, berries, citrus, grapes, mushrooms, and tomatoes, Costa Group required comprehensive storage solutions to support their expanding operations. The project encompassed multiple sites including facilities for fertilizer storage, cold storage, and general warehouse operations to maintain their position as Australia's premier fresh produce company.
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- The Solution
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The Challenge
Costa Group faced several critical operational challenges across their facilities:
- Storage Capacity Constraints As Australia’s largest horticultural company, Costa needed to significantly expand their storage capacity to accommodate growing inventory volumes while maintaining product quality and accessibility.
- Temperature-Controlled Storage Fresh produce operations required sophisticated cold storage solutions to preserve product quality and extend shelf life, necessitating both refrigeration systems and appropriate racking solutions.
- Facility Damage and Maintenance Existing drive-in racking systems across multiple sites had sustained damage requiring immediate repair and replacement to maintain operational continuity.
- Diverse Product Storage Requirements Different product categories required specialised storage solutions – from high-density drive-in racking for bulk storage to selective pallet racking for more varied inventory access.
- Multi-Site Coordination Projects needed to be coordinated across multiple locations including main facilities, fertiliser sheds, and mixing shed
The Solution
Storeplan developed a comprehensive multi-site storage solution tailored to Costa Group’s agricultural and distribution requirements:
High-Density Drive-In Racking Systems
- New SSI Drive-In System Complete 4-level high-density storage system providing additional pallet spaces, maximising storage capacity for bulk produce storage
- Drive-In Racking Seamless integration drive-in systems, adding capacity while maintaining operational workflow
- Bulk Storage Solutions Large-scale drive-in racking accommodating single pallets with 4-level storage heights
Temperature-Controlled Storage Infrastructure
- Cool Room Construction Custom insulated panel construction creating sealed cold storage environment with professional-grade refrigeration systems
- Refrigeration Equipment Dual-system refrigeration setup with package condensing units, evaporators, and digital controllers maintaining optimal temperatures for fresh produce
- Structural Support Engineered steel support systems ensuring structural integrity for cold storage operations
Facility Repairs and Upgrades
- Multi-Site Damage Repairs Comprehensive repair programs across various Costa sites addressing damaged upright posts, diagonal braces, and horizontal braces
- System Integration Seamless integration of new components with existing racking systems
- Safety Enhancements Installation of upright protectors, SWL signage, and safety systems across all locations
Specialised Storage Solutions
- Fertiliser Shed Systems Selective pallet racking designed specifically for agricultural chemical and fertiliser storage with safety considerations
- Mixing Shed Operations Purpose-built selective racking systems supporting agricultural mixing and processing operations
- Flexible Access Systems Strategic combination of drive-in and selective racking to optimise both high-density storage and operational accessibility
Summary
The Costa Group project demonstrates Storeplan’s ability to deliver comprehensive storage solutions for Australia’s largest horticultural operation. By addressing the unique challenges of agricultural storage, temperature control, and multi-site coordination, Storeplan enabled Costa Group to maintain their market-leading position.
The integrated solution delivers:
- Maxisimised Storage Capacity High-density drive-in systems significantly increased storage capacity while maintaining operational efficiency
- Quality Preservation Professional cold storage infrastructure ensuring optimal conditions for fresh produce storage and distribution
- Operational Continuity Comprehensive repair and upgrade programs minimising downtime across multiple facilities
- Safety and Compliance Enhanced safety systems and structural integrity supporting Costa’s commitment to workplace safety
This project reinforces Costa Group’s position as Australia’s premier fresh produce company, providing the storage infrastructure necessary to support their continued growth and their commitment to supplying quality fruits and vegetables to major Australian supermarket chains and export markets. The enhanced facilities enable Costa to maintain their industry leadership while supporting their expanding operations across multiple product categories and geographic locations.
