How a supermarket chain got a 21,500 ft² cold DC with no construction

A supermarket chain in Lima, Peru needed a complete cold distribution center: storage, picking, aisles, receiving and shipping. Instead of building one, it chose a modular distribution center from ZGROUP. The result is the largest modular cold storage facility in the Americas, delivered with no construction, no upfront capital and a dedicated PowerPack as backup against grid outages.

The challenge

A supermarket chain moves a steady flow of refrigerated product from suppliers to stores. That requires more than a cold room. It needs a real distribution center: space to receive, store, pick and ship, laid out so product keeps moving.

Two constraints shaped the project. The chain did not want to tie up capital in a permanent building, and the facility had to keep product protected even when the local grid went down.

The solution

ZGROUP designed and delivered a full modular DC built from ZSTORE XL modules, covering more than 21,500 ft². The facility includes:

• Cold storage areas
• Picking areas and aisles
• Receiving and shipping areas
• A dedicated PowerPack as backup against grid outages

It was delivered turnkey, with no construction and no upfront capital expenditure for the chain.

The results

• 21,500+ ft² of floor area
• Full DC: multi-zone distribution in one facility
• No CAPEX: delivered turnkey

It stands as the largest modular cold storage facility in the Americas.

When does a modular distribution center make sense?

A modular distribution center applies the same building blocks as a single walk-in, at the scale of a warehouse. It tends to make sense when:

• You want to avoid a construction project. Modular units need no civil works or permanent construction and only minimal site prep.
• Capital is better spent elsewhere. Units are available to rent or to buy, so the facility does not have to start as a large upfront investment.
• You run several temperatures. XL modules connect side by side into open space, and zones can run at different temperatures, such as a cooler area next to a freezer area.
• Your footprint may change. Each XL module adds 320 ft² and about 20 pallet positions, and modular units can be moved and reinstalled at another site.

Efficiency at scale

Because XL modules share the space, a connected layout needs fewer refrigeration units per square foot than a yard full of single containers. The cold storage line covers -40°F to +122°F (-40°C to +50°C), with humidity control from 50% to 95% RH available for products that need it. ZTRACK remote monitoring reports temperature and alarms across the facility, and refrigeration is by Thermo King with a 5-year warranty.

Planning around the flow

Design a modular DC the way product moves through it: receiving, storage, picking, then shipping. Aisles and staging areas count as much as storage positions, because they decide how fast orders leave the building.

Plan for outages too. In this project, a dedicated PowerPack serves as backup against grid outages, and ZTRACK alarms flag temperature problems so the team can act before product is at risk.

Finally, think about growth. Because each XL module adds a known amount of space, a modular DC can be planned in phases: start with the zones you need today, then connect more modules as store count or volume increases, without rebuilding what is already there.

Is it right for your operation?

If you need distribution capacity without a construction timeline or a large capital outlay, a modular DC can be designed around your flow. Explore ZSTORE XL modular cold storage and our modular distribution center options, or talk to our team about your layout.