Major Manufacturer Boosts Storage Rack Capacity by 28% Without Expansion | Apex Project Spotlight

Smart Storage Rack Solutions: A Manufacturer’s Path to Enhanced Capacity

A leading manufacturer faced a pressing challenge: they needed to increase storage rack capacity amidst growing production demands without expanding their existing facility or disrupting daily operations.

The Apex team delivered a comprehensive strategy to boost the warehouse’s storage space by an impressive 28%! With a combination of existing storage racking and new storage solutions, we created over 6500 pick locations and 23,547 new pallet positions. 

Here’s how we achieved it:

A. Implemented Pick Locations with Carton Flow Rack

• Racking Retrofit: The bottom beam level of nine back-to-back rows of selective racking was removed, and the second level was raised to accommodate four new carton flow-equipped pick levels.
• Increased Bin Locations: We installed snap-on dividers on each beam level, creating six SKU lanes per level. This transformed two pallet positions into 24 customizable SKU slots per bay.
• Enhanced Capacity: A new retrofit design replaced 1,002 pallet positions to create 6,024 new carton locations, significantly increasing storage density and flexibility.

Standalone Carton Flow Rack System	Snap-On Carton Flow Dividers

B. Expanded Storage Rack Installations

In addition to the retrofit projects, our team added 830 bays of storage rack with various elevations to meet specific operational needs, ultimately creating an additional 540 bin locations and 21,532 pallet positions.

• 24 bays of carton flow racking.
• 112 bays of back-to-back single selective racking.
• 694 bays of double-deep racking with two- or three-deep pallet flow systems on the bottom level.
• Safety netting on the double-deep rack protects adjacent pedestrian areas.

C. Optimized Traffic Flow

• Tunnel Creation: We removed three bays in a line from 16 rows of selective racks to create a tunnel that aligned with the rest of the warehouse, facilitating smoother forklift and pedestrian movement.
• Safety Enhancements: Modified existing safety netting by cutting, rolling, and re-securing it to the adjusted racks, ensuring the safety of associates during pallet loading and picking.

D. Modified Pallet Racking to Protect Inventory

 

In 1,456 bays of double-deep pallet racking, we installed beams 12 inches off the ground and added wire decking. Raising products off the floor enables cleaning under the rack and protects products from accidental strikes by passing equipment. This modification maintained the storage space in the system.

While the Apex team worked on this initial phase of the project, operations were minimally affected with continued access to the surrounding racking.

Through strategic planning and clever storage solutions, the Apex team significantly boosted the warehouse’s capacity, increasing pallet positions from 85,800 to 109,347—a remarkable 28% surge. Coupled with the highly efficient pick locations for single items and cases, the reconfigured space meets current demand… and prepares this busy manufacturer to handle future growth.

Our commitment to delivering customized solutions that drive tangible results is evident in every aspect of this project. Whether you’re facing capacity challenges or seeking to enhance operational efficiency, Apex is ready to optimize your warehouse space. Contact us today to discover how we can tailor solutions to meet your specific storage and operational needs.