The core calculation
Shelf length needed (m) = Σ (facings per SKU × facing width in m). Run length (m) = shelf length ÷ number of shelf levels, including the base deck if you merchandise it. Then round up to the module lengths the maker builds, and check that the stock on shelf covers sales between refills.
Facing width is the width of one product plus a small gap, typically measured from your own packs. Average it by category; dairy pouches, curd cups, juice cartons and ready meals all differ.
Worked example: a dairy and chilled run
Assumptions: 120 chilled SKUs; average 1.5 facings each; average facing width 90 mm; 5 merchandising levels; usable shelf depth 500 mm with packs about 80 mm deep, so each facing holds 6 units deep.
| Step | Working | Result |
|---|---|---|
| Facings | 120 SKUs × 1.5 | 180 facings |
| Shelf length | 180 × 0.09 m | 16.2 m |
| Run length | 16.2 m ÷ 5 levels | 3.24 m |
| Round to modules | Assumed 1.25 m modules: 3 × 1.25 m | 3.75 m |
| Units on display | 180 facings × 6 deep | about 1,080 units |
Check the shelf holds enough between refills
Divide units on display by units sold between refills. If the store in the example sells about 900 chilled units on a busy day and restocks twice a day, it needs about 450 units on shelf between refills. 1,080 units covers this comfortably on average, but fast sellers like milk pouches run out first. Give them extra facings and accept fewer for slow lines rather than adding run length for everything.
Do not plan to store back stock in the multideck. It belongs in a backroom cold store or reach-in, where doors stay closed.
Open front or glass doors in an Indian store
Open multidecks rely on an air curtain to hold cold air in the cabinet. That curtain works within the store climate the cabinet was tested for. Display cabinets are tested in defined test-room climates under ISO 23953; ask which climate class a model was rated in and compare it with your store on a humid summer evening.
In non-AC stores, near entrances, or under ceiling fans and AC outlets that blow across the front, open cabinets struggle and spill cold air into the aisle. Glass doors reduce that loss and suit Indian conditions better in many stores, at the cost of a slower shopping experience.
Layout checks before you fix the length
- Leave space at both ends of the run for end panels and for the cabinet's own clearance requirements.
- Integral (plug-in) multidecks reject their heat into the store. The net heat added to the room is roughly equal to the electricity the cabinets use, which your store AC must then remove.
- Remote multidecks reject heat outdoors through a condensing unit, which needs space, pipe routes and access.
- Keep the run away from entrance doors, direct sun and AC diffusers pointed at the air curtain.
- Check the floor drain or condensate arrangement for each module.
Planning for growth
If you expect to widen the chilled range within a year or two, reserve floor space at the end of the run and ask whether the electrical and, for remote systems, refrigeration piping can be extended. Adding a module to an existing run is easier than moving the run later.
Frequently asked questions
- Is there a standard metres of chiller per square metre of store?
- No. It depends on the store's format and how much of its turnover is chilled. A neighbourhood store selling milk, curd and paneer may need more chilled length than a larger store focused on dry groceries. Plan from your range and sales.
- Should I count the base deck as a shelf?
- Only if you actually merchandise on it. Many stores use the base deck for bulk or multipack lines. If you leave it for overflow, plan run length on the upper shelves alone.
- Can visi coolers replace a multideck?
- For a small store, a row of glass-door visi coolers can be a practical substitute: doors hold cold well in warm shops and units can be added one at a time. The trade-off is less continuous display and more doors for shoppers to open.
