Project brief
Our client faced the challenge of accommodating expanding inventory while maintaining efficiency in order fulfillment. They needed a high-density storage solution that was flexible, scalable, and ensured safe handling of their wide product range.
The challenge
To design a adjustable pallet racking system that would not only increase storage capacity but also streamline operations and future-proof our clients logistics operation.
Solution
Stamina worked closely with the client to understand their exact needs. From the conceptual design phase to multiple iterations of racking layouts, Stamina paid close attention to every detail and anticipated potential operational challenges. One of the key aspects was ensuring optimal aisle clearance, which was critical for the efficient maneuvering of articulated trucks. Stamina’s consultative approach, which included involving the forklift truck company, enabled them to confirm their recommended design and win the client’s trust.
Key Features of the New Warehouse Design
- Adjustable Pallet Racking System(Single entry / Double entry runs): The new system allows for a more flexible configuration, accommodating future changes in inventory size or shape. Designed to accommodate pallets with dimensions of 1,000mm (width) x 1,200mm (depth), each capable of holding up to 1,000kg.
- Optimised Aisle Clearance: By allowing for efficient forklift operation, the design enabled seamless access to pallets while avoiding wasted space.
- Heavy-Duty Protection Systems: Incorporation of Stamina’s Protect-It XL upright protectors and heavy-duty rack end barriers minimised the risk of damage from forklifts or other equipment, ensuring long-term reliability.
- Walk-Under & Drive Under Access: A unique design feature warehouse staff to easily walk beneath the racks, as well as forklift access, improving accessibility and safety at the ground level without compromising on storage capacity.
- Mesh Decks: Mesh decking was installed on the bottom levels of the drive-under sections to provide additional support and prevent items from falling.
- Fire Escape and Anti-Collapse Mesh: To comply with safety regulations, anti-collapse mesh was fitted on the back of two bays in the smaller single-entry run. This mesh also facilitates fire escape routes while maintaining the integrity of the racking.
Results
The new storage system installed by Stamina provided the client with approximately 3,500 pallet positions, maximising the space and enabling smooth operations. The innovative design removed previous operational restrictions, significantly enhancing order picking, packing, and shipping efficiency. Additionally, the implementation of heavy-duty protection systems ensured the longevity of the racking, reducing the risk of damage and maintenance costs over time.
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