Custom Hot-Dip Galvanized Stacking Rack Fabrication Case Study

1. Client Background & Project Requirements

A well-established cold chain storage provider in Rotterdam, Netherlands, served as the client for this project. They support the European fresh food, pharmaceutical, and import/export industries. To expand their -18℃ low-temperature warehouse capacity, the client commissioned DEEPLINK for custom hot-dip galvanized stacking rack fabrication, producing heavy-duty stackable metal racks. These racks facilitate unitized vertical storage for standard Euro-pallets. Furthermore, the design supports multi-layer stacking and forklift operations. Crucially, the racks also withstand corrosive high-humidity and low-temperature environments.

Core Client Requirements:

• Product type: 200 sets of heavy-duty storage stacking racks, compatible with standard Euro-pallets.
• Load rating: Industrial-grade design for multi-layer stacking, adapted for mechanized forklift operations.
• Material specification: Q235B carbon structural steel with thickened rectangular tubes and bent steel plates.
• Environmental adaptability: Excellent rust and corrosion resistance for high-humidity, low-temperature cold storage.
• Surface finish: Uniform hot-dip galvanized treatment to meet long-term anti-corrosion requirements.
• Delivery terms: Complete production and shipping to Rotterdam within 40 days, including English instructions.
• Qualification requirements: ISO9001 certification, plus load test and zinc coating thickness reports.

2. DFM Optimization & Technical Coordination

The client first uploaded their 3D STEP drawings via the DEEPLINK website. Consequently, our engineering team completed a free Design for Manufacturability (DFM) analysis within 24 hours. By considering cold storage scenarios and mass production needs, we proposed four core optimizations:

1. Stacking positioning structure optimization: We upgraded the positioning structure using a precision welding process with fixture positioning. Specifically, dedicated jigs accurately secure the components while back-step welding controls deformation. This ensures high precision and batch consistency. As a result, we improved alignment accuracy and eliminated slipping risks during forklift operations.
2. Base structure upgrade: The main base beam now uses an integrated CNC bending process. This enhances structural integrity and stress distribution. Moreover, it improves torsional strength and ensures stability under heavy loads.
3. Hole process optimization: We produce connecting holes using a progressive die continuous stamping process. This controls position accuracy within ±0.2mm. Therefore, all batch parts achieve 100% interchangeability for quick on-site assembly.
4. Galvanizing process optimization: We applied passivation and fillet treatments to all corners and pipe orifices. This avoids zinc spangles and sagging during hot-dip galvanizing. Consequently, we ensured uniform coverage and improved the anti-corrosion lifespan.

After the client confirmed the plan, DEEPLINK produced a full-scale sample within 3 days. Once the client verified the stacking performance and quality, they approved mass production.

3. Full-Process Production Implementation

This project utilized DEEPLINK’s full-chain sheet metal fabrication capabilities. Specifically, we covered every step from raw materials to finished products. The core production links included:

1. Laser cutting: We used 6000W fiber laser cutters for steel plates and pipe ends. This resulted in smooth edges and linear tolerances within ±0.1mm.
2. CNC bending forming: Our 160-ton CNC press brakes completed one-piece forming for bases. Consequently, we ensured stable structural stress with minimal angle deviation.
3. Progressive die stamping: We batch-stamped positioning structures and connecting holes. This process significantly improved production efficiency and consistency.
4. Precision welding assembly: We applied CO₂ gas shielded welding for the main frame. Furthermore, key load-bearing positions received full-length welding. All welds underwent visual and ultrasonic inspections to eliminate defects.
5. Hot-dip galvanizing treatment: Workpieces received pre-treatment before entering the hot-dip galvanizing bath. We strictly controlled temperatures and dipping times. As a result, we achieved uniform thickness and excellent adhesion.

DEEPLINK completed the 200 sets in just 32 days. This was 8 days ahead of schedule, thanks to our 80% automation rate across 6 production lines.

4. Comprehensive Quality Control System

The entire project followed the ISO9001:2015 system. Specifically, we used 39 quality inspection nodes across the production cycle:

• Incoming inspection: We analyzed material properties to ensure the steel met Q235B standards.
• In-process inspection: Each process included first-article confirmation and batch sampling. Moreover, we performed full inspections for critical dimensions.
• Finished product inspection: We verified dimensions, welding quality, and zinc coating adhesion.
• Performance verification: We tested 3 random sets under full load for 72 hours. Consequently, we confirmed that deflection remained well within industry standards. Additionally, zinc coating samples passed salt spray tests.
• Compliance certification: The finished products meet SGS, ROHS, and REACH standards.

5. Surface Treatment

We adopted a hot-dip galvanizing solution for the corrosive cold storage environment. First, workpieces underwent pickling and rust removal. Next, high-temperature hot-dip galvanizing formed a dense protective layer. Finally, post-plating passivation removed surface spangles. Consequently, we improved the durability and appearance of the racks.

6. Delivery & Client Feedback

The goods arrived at the Port of Rotterdam after 32 days of ocean freight. Throughout the process, DEEPLINK tracked every logistics milestone. We also provided the client with all necessary customs documents in advance. As a result, the client completed customs clearance and on-site assembly smoothly.

7. Case Summary

This project highlights DEEPLINK’s expertise in heavy-duty storage components. We offered several key advantages:

• Front-end technical empowerment: Our free DFM analysis optimized performance and reduced costs early in the design stage.
• Full-chain process capability: We managed everything from laser cutting to hot-dip galvanizing in-house. This allowed us to control quality and lead times effectively.
• Strict quality standards: Our ISO management and testing met the highest industry application requirements.
• One-stop delivery: We provided a seamless service from drawing optimization to export logistics.
• Efficient response mechanism: Our 24-hour support successfully met the client’s customization and production needs.

DEEPLINK continues to provide customized metal fabrication solutions for high-end logistics clients worldwide.