Here at Advanced Handling and Storage Ltd we know that a well-designed warehouse can increase operational efficiency by up to 30% and reduce overall costs by as much as 15%. If you optimise your layout, you not only speed up your order fulfilment but also significantly minimise the risk of workplace accidents, making them a critical factor in the success of any business and the health and safety of your staff. 

To make your warehouse efficient, strategically arranging your space, storage, and flow will maximise the productivity of your staff, ensuring a smooth run, accessible inventory, and essential timely operations. So whether you’re setting up a new warehouse or want to rearrange an existing one, let us take the stress out of your design with our expertise and commitment. 

Understand Your Warehouse Layout

Before you begin designing your efficient warehouse layout, it’s crucial to have a clear understanding of the storage solutions needed and how you will manage your inventory. For example, when it comes to products, you may need larger space for bulky items, cold storage for perishables, and different heights or hazardous levels. 

Ensure you map your warehouse correctly when designing your layout, including office spaces, toilets and canteens. When arranging workstations and storing goods, there are various approaches to consider. Using an organised cluster approach, which groups products according to type is one method, and allows every worker easy access to each cluster or arranging your storage in aisles is another popular method, with production and workflow in front and aisles in back.

If you plan appropriately, everything should fit in its place; if not, start over from scratch and make sure you are utilising all of the vertical space whenever possible. Stacking products will expand your storage capacity and make the most of the available area.

We recommend determining your available space and setting aside 22–27% of that for your entire product storage capacity.

What Storage is Suitable for Me?

When it comes to your warehouse storage, we recommend leaving between 3.6 and 3.9 metres between aisles to accommodate your forklift and ensure everything is safe. 

Let’s take a look at some of the types of storage you may require;

Pallet Racking: Perfect for bulky or oversized items. Systems for pallet racking are very adaptable, and we’re happy to offer you a bespoke fit for your warehouse that enables you to use your vertical space effectively. Pallet racking systems like selective, drive-in, or push-back offer different benefits depending on your inventory needs.

Shelving: Ideal for lighter and smaller objects, shelving systems are easily accessed and can be positioned to optimise available space in compact spaces. They are the perfect addition to schools, office spaces, or areas where picking and packing are prominent.

Speciality Storage: The selection of storage systems, such as refrigerated storage, will be influenced by whether the products in your inventory require certain conditions. 

Once you have identified which storage is the perfect pick.  Take the time to think about where your warehouse is seeing inefficiencies, this will allow you to map out and plan your warehouse layout efficiently. A thorough examination of the flow of items through the warehouse, including receipt, storage, picking, packing, and shipping, can identify bottlenecks and needless motions that hinder efficiency. 

Warehouse Racking Layout 

An excellent way to ensure your layout works well for your company is to make sure you have a clear separation of zones in your warehouse; some layouts that might work for you are:

• Receiving Area: Located near the warehouse’s main entrance to streamline the unloading process, a well-designed receiving area should include designated space for inspecting incoming goods before they are moved to storage. 
• Shipping Area: Similarly, the shipping area should be positioned near the warehouse exit to facilitate quick and efficient loading of outbound equipment. Consider placing high-turnover products closer to the shipping area to reduce picking times and improve overall efficiency in your daily operation.
• Narrow vs. Wide Aisles: The choice between narrow and wide aisles depends on your storage needs and the equipment used. Narrow aisles maximise storage space but require specialised equipment like narrow-aisle forklifts. Wide aisles, on the other hand, allow for easier manoeuvrability and faster picking but reduce overall storage capacity.
• U-Shaped Design: Set up in a semi-circle, this simple design is an excellent option for your warehouse; place the loading and shipping areas close to each other for behind loading and the picking area behind shipping. 

• Through-Flow: A brilliant option for high-volume warehouses with the loading and unloading area at one end and the shipping on the other, with storage in the middle section. 

Our Top Tips for Warehouse Racking Layout 

1. Loading and Unloading: Dedicate plenty of space to prevent bottlenecking in your warehouse. 

2. Separate Reception: This ensures a good flow in your warehouse regarding sorting and inspecting. 

3. Utilise Space: Use vertical space that would otherwise be wasted. Consider a mezzanine floor for this. 

4. Picking: Ensure picking areas are close to storage for easy access to items. 

5. Shipping: Keep shipping separate from the rest of your operations to ensure good traffic flow. 

Contact us for expert site inspections or tailored guidance on making the most of your warehouse space. Considering your inventory type, zoning, and increasing safety, we’re confident we can help you plan the perfect layout for your new or second-hand pallet racking.