The design of your warehouse storage system can make or break your operations. A well-thought-out plan improves productivity by reducing unnecessary travel time, streamlines picking and packing processes, and helps optimise space usage to save on costs. Additionally, a scalable system ensures you can adapt to growth without needing to redesign your warehouse every few years. Safety also plays a critical role; implementing systems that comply with standards protects both your employees and inventory, reducing risks and liabilities.

Choosing the right storage system is key to optimising space and efficiency. Pallet racking systems are among the most common options, offering flexibility and scalability. Adjustable Pallet Racking Systems for example, are ideal for warehouses with varied SKUs that need fast access. For higher-density needs, push-back racking works well with LIFO (last-in, first-out) inventory systems, while drive-in racking maximises storage for large quantities of similar products.

If your inventory includes smaller, hand-picked items, long span shelving systems are a better fit. Static shelving works for lightweight goods, while mobile shelving can maximise space by reducing the need for fixed aisles. For warehouses with limited floor space, mezzanine floors provide a cost-effective solution by utilizing vertical space to add extra storage levels.

For long products like timber, pipes, or carpet rolls require unique solutions such as cantilever racking. These systems provide accessible, organised storage for irregular or bulky items. For businesses aiming for maximum efficiency, automated storage and retrieval systems (AS/RS) use robotics to optimise high-density storage and picking processes, improving accuracy and reducing labour costs.

An effective warehouse design layout ensures smooth workflows and minimises wasted time. Start by organising your warehouse into key zones: receiving, storage, picking, packing, and dispatch. The receiving area should have sufficient space for unloading and inspecting incoming goods before they move into storage. High-turnover items should be placed in easily accessible areas to speed up the picking process, while slower-moving items can be stored in less convenient zones.

Creating wider aisles in high-activity zones improve access for forklifts and pickers, reducing delays. Additionally, implementing a clear labeling and inventory management system will make it easier for employees to locate and identify products quickly, further boosting efficiency.

Warehouse planning often fails due to overlooked details. One common mistake is ignoring scalability. Your storage systems should adapt to growth rather than limit it. Another issue is underutilising space; many warehouses expand their floorspace unnecessarily instead of maximising vertical storage with taller racking systems or mezzanines. Safety is also critical but frequently neglected. Ensuring your systems meet load limits and safety standards protects both your employees and inventory.

Finally, poor workflow design can create bottlenecks that slow down operations. A disorganised warehouse layout increases travel time and reduces productivity, so carefully plan your zones and pathways to ensure a smooth process from receiving to dispatch.

Planning your warehouse storage requires careful consideration of space, inventory needs, and workflows. Whether you opt for pallet racking, heavy-duty long span shelving, or advanced automation, the right system will enhance efficiency, reduce costs, and prepare your business for future growth. By maximising both vertical and floor space and ensuring a logical workflow, you can create a warehouse setup that supports your operational goals.

If you’re ready to take the next step, consider investing in storage systems tailored to your needs. From high-quality pallet racking to safety-compliant solutions, the right setup can make all the difference.

Use this blog to guide your warehouse design process – you can seek advice from the team at Stamina Storage Systems to help with this as they have many years experience in this area and will help you every step of your project.

Before you approach a warehouse redesign and layout, it’s important to identify the specific challenges you are faced with during peak times.  Are there delays in order picking? Are you struggling with limited storage capacity? Do bottlenecks form in certain areas of the warehouse? Understanding these key pain points will help focus your redesign efforts on areas that will have the most immediate impact.

Inefficient use of warehouse space is one of the most common issues we come across when visiting customers warehouses. You need to be asking yourself…Could you increase the vertical space that could accommodate increase the height of the pallet racking? Are you aisles unnecessarily wide, reducing storage capacity?  A useful task, is to conduct a space audit to identify opportunities for optimising the layout. Sometimes, simple changes like reconfiguring aisles, increasing the height of the racking, or introducing mezzanines can lead to significant improvements in storage efficiency.

If your business inventory needs and order patterns  have changed since your last warehouse design was implemented. A redesign of the warehouse gives you the opportunity to reorganise your storage based on product velocity, ensuring that high-demand products are positioned for quick and easy retrieval during peak periods.

There are many options and reconfigurations of pallet racking systems available, depending on the type business operation, adjustable pallet racking, drive-in racking, or double-deep racking may be more suitable. Consider how flexible your currant racking system is, and whether it can accommodate growth in inventory or new product lines. You may not need to upgrade your whole system, is could just be a simple solution like adjusting your current racking system. A pallet racking specialist, like Stamina Storage Systems can provide a free site survey to recommend the most suitable and cost effective options.

Warehouse Automation is increasing in popularity, therefore it’s this is an option consider how the technology will be integrated into your warehouse redesign. Are you planning to incorporate a Warehouse Management System (WMS), automated storage and retrieval systems (ASRS), or robotics? Consider these factors to ensure your layout can accommodate these systems to improve efficiency and reduce reliance on manual processes, especially during peak periods.

The layout of your warehouse will have a direct impact on how efficiently and safely your employees can work. Are your order pickers able to move quickly between different areas of the warhouse? Are there clear paths for forklifts and foot traffic? Are products organised in a way that minimises heavy lifting or reaching? A redesign can help improve the ergonomic conditions for your employees, reducing accidents and increasing overall productivity during busy times.

Depending on the nature of your business, certain products may be more in demand during specific times of the year. For example, Black Friday, or Christmas holidays, or during seasonal changes. Understanding changes in demand for your products is really important in helping you design a warehouse that can flexibly enough to accommodate different needs throughout the year.

A successful warehouse redesign should improve the operational flow of products through your storage facility, from receiving and storage to picking, packing, and shipping. Take a close look at your current workflow and identify areas where delays occur. Does the current layout cause congestion in various key areas? Would a new picking method or route optimisation help speed things up? Use this insight to guide the redesign process – you can seek advice from the team at Stamina Storage Systems to help with this as they have many years experience in this area.

A warehouse redesign does come at a cost, but it’s important to understand the potential return on this investment for the business. You will need to consider the costs associated with redesigning, including potential disruptions to operations. Then, weigh that against the anticipated improvements in productivity, reduced labor costs, and increased storage capacity. A clear understanding of the ROI will help you justify the redesign to upper management and stakeholders.

Finally, how will you measure whether the redesign has been effective? Consider key performance indicators (KPIs) such as order picking speed, accuracy, throughput, labor costs, and safety incidents. Establish a timeline for when these metrics will be evaluated after the redesign to ensure that you are hitting your targets.

Most warehouses operate under demanding conditions and therefore require storage solutions that can withstand heavy loads, frequent usage, and tough environments. Below we have highlighted the key reasons why heavy-duty industrial shelving could be the perfect option for your warehouse.

1.  Durability and Strength

One of the main benefits of choosing heavy-duty industrial shelving is its ability to handle significant weight. Our shelving units are built with robust materials like high-gauge steel, making them capable of supporting large loads up to 1000kg per level without bending or warping.

2. Space Efficiency

In a busy warehouse, maximising storage space is critical. Our industrial shelving systems are available in various widths and heights, designed to make the most of both vertical and horizontal space, allowing you to store more products in a smaller footprint. They also have adjustable shelves providing flexibility, and a choose of levels, ensuring your storage solution can adapt to different product sizes and weights.

3. Easy Accessibility and Organisation

Heavy-duty shelving systems can help you organise your warehouse efficiently. With clear visibility of stored items and the ability to tailor the shelf configurations, your team can quickly locate and retrieve items, making them a great choice for picking, and storing lots of different SKUs. This boosts productivity and reduces the time wasted searching for products.

1. Low Maintenance

Our shelving systems require minimal upkeep. They are made from high-quality materials, that resist corrosion, scratching, and wear, they remain in top condition even in the harshest warehouse environments. This reduces maintenance costs and ensures the longevity of your shelving units.

2. Cost-Efficient

While our shelving solutions are of premium quality, they come at competitive prices. The long-term savings due to durability, low maintenance, and fewer replacements make them an affordable option for businesses looking to invest in reliable warehouse storage. Check out our latest deals

3. Customised To Your Requirements

Every warehouse has different needs. Our shelving systems are available in a range of sizes, load capacities, and configurations, allowing you to tailor your purchase to your specific requirements. This customisation helps you avoid overspending on unnecessary features, making your investment even more cost-effective.

4. Environmentally Friendly Materials

Our shelving is made from recyclable materials, contributing to sustainability goals. Choosing eco-friendly storage solutions not only helps the planet but can also improve your company’s reputation with customers and stakeholders who value environmental responsibility.

• Quality Material
  Our industrial heavy-duty shelving systems are built with premium steel. Utilising cutting-edge production technology and stringent quality control processes, we guarantee the durability and performance of every product we deliver.
• Quick Delivery – 2-4 days
  At our expansive warehouse facility, we maintain a substantial inventory of shelving to meet the most common requirements across various industries. This allows us to efficiently cater to our clients’ needs and adhere to tight project timelines. Most orders of shelving, can be be delivered / or pickup with 2-4 working days from the order being placed.
• Free consultation and Design
  If you have a large warehouse, and need advice and guidance on the various options, our expert team are on hand to help. We can offer a free site visit to assess your requirements and provide a detailed design layout to ensure maximum space utilisations. Contact us to book a free site survey 

If you handle and store heavy-duty goods you  storage solutions that can handle the weight and volume of their inventory without compromising on safety or efficiency. Here’s why our high capacity pallet racking is a must for businesses dealing with heavy loads.

Investing in a high capacity pallet racking system offers numerous benefits that can positively impact your business operations.

High capacity pallet racking is specifically designed to bear heavy loads. These systems will have larger beams widths (around 100mm -120mm) , and additional bracing to support more weight than standard racking systems. This increased load-bearing capacity means you can store heavier items safety and securely.

With a well-organised high capacity pallet racking system, your warehouse operations become more efficient. Employees can quickly locate and retrieve items, reducing downtime and improving productivity. Additionally, these systems can be customised with accessories such as mesh or timber decking, as well at added safety measure such a rack protection.

While the initial investment in high capacity pallet racking may be higher than standard options, the long-term benefits make it a cost-effective choice. These systems are built to last, reducing the need for frequent replacements or repairs.

Before choosing a pallet racking system, it’s important to understand the weight and size of the items you need to store. This will determine the type of racking that is suitable for your operations. Consider factors such as the maximum load weight, the dimensions of your inventory, and how often items will be accessed.

There are various types of high capacity pallet racking systems available, each designed for different applications. Some common types include:

• Adjustable Pallet Racking(APR): This is the most common type of direct access pallet racking. It allows for individual pallets to be accessed directly without moving others. Adjustable pallet racking, also knows as selective pallet racking are versatile and suitable for warehouses with a wide variety of SKU (stock-keeping unit) requirements. They offer easy access to each pallet, making them ideal for businesses that prioritise quick retrieval of goods.

• Cantilever Racking: a specialised type of pallet racking system designed primarily for the storage of long, bulky, or irregularly shaped items that cannot be stored on traditional pallets. Unlike conventional pallet racking, which utilises horizontal beams to support pallets, cantilever racking features long, horizontal arms that extend from vertical columns.

• Mobile Racking Systems: Unlike traditional static pallet racking, mobile pallet racking is mounted on a steel framed base. This racking system is installed over guided mobile bases that slide laterally, thus eliminating the need for aisles, which open up only when accessed.

• Drive-In Racking: Drive-in Racking, also know as drive-through racking, allows forklift trucks to drive directly into the pallet racking , providing easy access to stored pallets. This efficient design eliminates the need for aisles between racks, maximising storage space for products with a low inventory turnover rate.

• Push Back Racking: Push back racking is a type of selective pallet racking system used in warehouses to maximise storage density while maintaining selectivity and ease of access to stored goods. Ideal if you’re storing bulk goods on pallets according to the Last-in, First-out (LIFO) principle.

Incorporating high capacity pallet racking for heavy loads into your warehouse is a smart investment that can enhance efficiency, safety, and productivity. By choosing the right system tailored to your specific needs, you can optimise your storage space, improve operational workflows, and set your business up for long-term success.

Whether you’re upgrading an existing warehouse or planning a new facility our expert team at stamina Storage Systems , can help you choose the right high capacity pallet racking systems for your business. To discuss your project, get in touch today!

Push Back Racking is a type of storage system that allows for high-density storage of products with selectivity. Unlike traditional racking systems, where products are loaded and unloaded from the same aisle, Push Back Racking operates on the principle of “last in, first out” (LIFO). This means that the last item placed on the rack is the first one to be removed.

The system consists of a series of carts that move along inclined rails. When a pallet is loaded onto the front of the rack, it pushes the existing pallets back, hence the name of the system “Push Back Racking.” As more pallets are added, they push the earlier ones further back, creating a sequence of easily accessible inventory.

1. High-Density Storage

One of the main benefits of choosing Push Back Racking is its ability to maximise storage space. By utilising the depth of the racking, it allows for more pallets to be stored in a smaller footprint compared to selective racking systems. This makes it an ideal choice for warehouses with limited space.

2. Enhanced Selectivity

While Push Back Racking follows the Last In First Out (LIFO) principle, it still offers better selectivity compared to other high-density systems like drive-in racking. Operators can access any pallet in the row without having to move others, provided it’s the front-most pallet. This makes it easier to manage inventory and reduces the time spent retrieving items.

3. Operational Efficiency

The design of Push Back Racking allows for quick loading and unloading, reducing handling time and labor costs. The system’s inclined rails and rolling carts facilitate smooth pallet movement, minimising the effort required by forklift operators.

4. Versatility

Push Back Racking can store a wide range of products, from perishable goods to non-perishable items. It is suitable for any business with items of different  sizes and turnover rates, making it a versatile solution for different industries.

5. Safety and Durability

The robust design of Push Back Racking systems ensures long-term durability and safety. The nested carts and rails are engineered to withstand heavy loads and frequent use. Additionally, the system’s structure minimises the risk of accidents, as forklifts do not need to enter the racking system to access pallets.

1. Retail and E-commerce

Retail and e-commerce businesses often deal with a high volume of products and frequent stock turnover. Push Back Racking is ideal for storing items with high turnover rates, allowing for efficient stock rotation and easy access to products.

2. Food and Beverage Industry

In the food and beverage industry, where shelf life and product rotation are critical, Push Back Racking provides an excellent solution. It allows for the storage of perishable goods with moderate rotation, ensuring that older stock is used first.

3. Manufacturing

Manufacturing facilities often require efficient storage solutions for raw materials and finished goods. Push Back Racking offers a space-efficient way to store various products, from small components to large assemblies.

4. Cold Storage

Push Back Racking is well-suited for cold storage environments, where maximising space is crucial due to the high cost of temperature-controlled facilities. The system’s design minimises the amount of time that forklift operators need to spend in cold areas, improving operational efficiency and employee comfort.

Push Back Racking is a versatile and efficient solution for businesses looking to optimise their storage space. With its ability to maximise space, improve access, and handle a variety of products, it’s a great choice for many industries. And with the help of Stamina Storage Systems, you can easily set up a Push Back Racking system that’s tailored to your needs. So if you’re ready to take your warehouse efficiency to the next level, get in touch to see how they can help!

To speak to our team, or arrange a free site visit, get in touch today.

Drive-in racking is perfect for high-density storage, especially for products that are stored in large volumes. This system allows forklifts to drive directly into the rack, which is great for maximising space.

If you need a FIFO system, carton flow racking is your best bet. Gravity rollers allow pallets to move forward automatically as items are removed. This system is ideal for perishable goods, and can not only improve stock rotation but also reduced labour costs as the need for manual handling was minimised.

Mobile racking systems are a fantastic space-saving solution. These racks are mounted on mobile bases that can be moved to create access aisles only when needed. Installing this type of racking system in a cold storage unit can increase your usable space allowing for more product storage without additional construction costs

Double deep racking balances accessibility and storage density. By placing one pallet behind another, you can store more products while still having relatively easy access. In a project with a beverage company, we used double deep racking to store large quantities of bottled water and soft drinks. This setup improved their storage efficiency while keeping their products easily accessible.

Industrial Shelving Systems are the backbone of modern e-commerce warehouse operations, offering innovative solutions that maximise every inch of space, streamline processes, and ultimately drive business success. In this blog, we will explore the various types of industrial shelving systems available from Stamina Storage Systems and how they can offer a plethora of benefits for optimal e-commerce efficiency.

Many E-commerce warehouse facilities face unique challenges, including managing a wide variety of stock, fluctuating inventory levels, and the need for quick order fulfillment. By choosing the right industrial shelving system for your business you can address these challenges by:

Efficient storage solutions are crucial for the success of any e-commerce operation, and investing in industrial shelving systems can maximise the storage capacity. The e-commerce warehouse stock a wide range products, from small parts like electrical, to much bulkier items like clothing. A shelving system, such as Longspan Shelving, known for its versatility and robust design, is a particularly effective solution. It typically consists of steel frames and adjustable beams. The design allows for easy assembly and adjustment, and to make the best use of vertical space, allowing businesses to store more items in the same floor space. This is particularly beneficial in e-commerce warehouses where maximizing storage capacity is essential.

In a fast-paced e-commerce warehouse, quick and easy access to stock is paramount. Industrial Shelving Systems, such as Mobile Shelving Systems are designed to significantly enhance inventory management and maximise accessibility. These systems consist of shelving units mounted on tracks, allowing them to be compacted together to save space and only create aisles when needed. This design not only increases the storage capacity within the same footprint but also improves the organisation of inventory, as items can be stored systematically and accessed with ease.

Industrial shelving systems are inherently adaptable, making them ideal for managing fluctuations due to seasonal trends in e-commerce. These shelving units feature adjustable components, such as customisable shelf heights and modular designs, allowing for quick reconfiguration to accommodate varying inventory sizes and quantities. During peak seasons, when stock levels surge, additional shelves can be added or repositioned to maximise storage capacity and improve organisation. Conversely, during off-peak periods, shelves can be rearranged or removed to create more efficient pathways and streamline the warehouse layout. This flexibility ensures that storage solutions remain efficient and effective year-round, regardless of changes in product volume or size.

Inventory management is a key factor in e-commerce operations. Shelving systems can help streamline this process by enabling efficient stock rotation and easy stocktaking. By implementing a system like Carton Flow Live Systems to ensure that products are easily visible, reachable, and ready for quick retrieval.

 In the fast-paced world of e-commerce, efficient shelving systems are essential for staying competitive. By investing in innovative industrial shelving solutions from Stamina Storage Systems, your businesses can maximise storage capacity, streamline operations, and ultimately achieve greater success. Whether you’re a small business or a large retailer, we can help you choose the the right shelving system can make all the difference in your operational efficiency and bottom line. So get in touch with our team today.