Category: Warehouse Boom

Tips on How to Effectively Plan a Warehouse Layout Design

Principles of an Efficient Warehouse Layout

Before you start designing your warehouse, you should understand what you’re trying to achieve with your warehouse layout design.

Here are 3 major principles to keep in mind when planning your warehouse:


Consider how to maximise the space you can afford, taking into consideration storage, stock, offices, working areas, empty pallet storage, battery charging, etc.

With a wide variety of vertical racks and freestanding equipment, you should be able to design your warehouse in the way you need it initially, while being flexible enough to change it in the future if desired.


Warehouse flow can be summarised as the uninterrupted movement of materials, people, and traffic within your building.

Your first goal should be to cut down on any areas of high traffic or potential for cross-flow crashes.

So, each activity that an employee performs must be located as close as possible to the activity that precedes it and proceeds from it.

That also means materials used to perform those activities should be situated as close as possible to each workstation.

Your second goal should be to eliminate as much movement and disruption as possible.


Every product and all products on pallets should be accessible by everyone, usually without the need to move one product to get to another.

That means structuring your pallet racks in rows that are wide enough to accommodate pallet jacks and trucks, and stacking and stocking items strategically for minimal interference with one another.

5 Critical Pallet Rack Safety Hazards

Physical damage to the pallet rack

Often this damage occurs from lift truck collisions. Sufficient clearance space and clear aisles are both great ways to prevent this kind of damage. Always encourage employees to promptly report all minor impacts or observable damage.

Misaligned Racking Safety Hazard

This can cause collapse or failure of your pallet racking system. During inspection, use the manufacturer’s instructions to check that racks are properly aligned, plum, and level.

Loose Floor Fittings

OSHA is clear that rack columns are bottom-anchored to the floor with column base plates secured with anchor bolts.

Suitability of forklift truck

Your material handling equipment and pallet jacks should be sized to meet your needs.

Weight of stored goods versus capacity of racking system

To prevent dangerously overloaded racks, ANSI/RMI MH16.1 suggests posting the maximum permissible unit load, average unit load, and maximum total load per bay.

In the end, whether your racks are damaged, overloaded, improperly anchored or misaligned, they’re a serious safety hazard that can result in serious injury. OSHA recommends warehouse managers develop a thorough maintenance and inspection program. Be liberal with safety audits that include everything from pallet rack signage all the way up your material handling equipment.

Drones Set To Power A Warehouse Boom

Drones may be a relatively new technology but they are about to become the next stage in a retail revolution that is transforming not only the way we shop but also the how goods are stored and distributed.

Amazon drones are already grabbing the headlines and ecommerce stores which were once simply a complement to established high street chains are now available to anyone who wants to set upo an online shop.

Yet even with drones and the internet doing a lot of the work, there is still the basic need to store those products and the simple warehouse is set to become a big draw for investors who sense that the returns in this sector are set to boom.

While drone technology is yet to become commonplace with issues such as the amount of drones that might be flying around at any given time, it is clear where things are heading. Drones are capable of dropping off an order less than 20 minutes after a button is clicked on a website.

The amount of infrastructure required to meet the demand for this type of service will spark a scramble for available warehouse space.

According to the latest figures, online shopping now accounts for 15% of all UK sales. Worldwide, ecommerce transactions are set to hit $4trn dollars by 2020.