In December 2024, we completed a comprehensive warehouse optimisation project for a growing client who was facing challenges with their storage capacity and operational efficiency. As their business expanded, the client found their existing warehouse systems increasingly inadequate to handle the increasing volume of products. They turned to us to help design and implement a custom solution that would enhance storage, improve picking processes, and streamline operations.
The solution we delivered involved a combination of high bay racking, a two-tier mezzanine floor, conveyors, and low-level picking solutions. Here’s how we approached the challenge and implemented the solution for the client.
Challenge
Solution
To address the client’s needs, we proposed a comprehensive solution that would not only optimise space but also streamline their picking and packing process. The key components of the solution included:
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High bay racking with anti-collapse screens: This solution utilised the full height of the warehouse, increasing storage capacity while keeping products safe and secure with anti-collapse screens.
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2-tier mezzanine floor (1500 sq. mtr): This addition maximised the vertical space in the warehouse, offering additional storage on the second tier while allowing for safe, efficient movement of goods between levels.
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Conveyors and parcel chute: The integration of conveyors and a parcel chute ensured that goods could be moved efficiently across the warehouse, speeding up the order fulfilment process.
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Low-level picking system: We incorporated a low-level picking area to allow warehouse staff to easily pick products from ground level, reducing the need for forklifts and improving picking accuracy.
This tailored approach allowed the client to make the best use of their existing space while improving efficiency across multiple areas of their operation.
Implementation
The implementation of these warehouse optimisation solutions was completed seamlessly, with our team working closely with the client to ensure all aspects of the project were executed according to plan. The steps involved were:
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Installation of high bay racking: We installed the racking systems that took full advantage of the warehouse’s height, ensuring safe storage for all items, and added anti-collapse screens to prevent damage to goods.
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Mezzanine floor setup: A 2-tier mezzanine floor was installed across 1500 sq. mtr of space, effectively doubling the available floor space for storage without the need to expand the physical warehouse footprint.
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Conveyors and parcel chute: Our team installed the conveyor system and parcel chute to improve efficiency in the movement of goods. This allowed items to be quickly transported across different areas of the warehouse.
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Low-level picking area: The low-level picking area was designed and set up to optimise the process of order picking, ensuring that the staff could access products quickly and easily without needing to use high forklifts or complicated systems.
While our team provided the full design and setup for the storage systems, the client took charge of certain operational tasks, which demonstrated the flexibility of our service. We ensured they had all the support and guidance necessary to complete the project smoothly.
