Smart use of space in non-obvious places in a distribution center

Many end-users of our partners, strive for growth, but encounter limitations in their storage capacity. These end-users often need more pallet spaces, while the available space seems limited because the logistics traffic has to continue on the floor. Together with our partners, we help that end-user still achieve this growth, even when it seems their current space does not allow for it. Our specialism lies in ‘finding’ additional storage capacity within the existing space, without disrupting the logistics traffic on the ground floor.

“We create space in non-obvious places within a distribution centre, without disrupting mobility”

‘Found space’

In busy distribution centres (DCs), floor space is often largely used for logistics traffic such as forklifts and order pickers. Yet there is often unused height space left over. We convert this ‘found space’ into extra storage space, thus increasing the DC’s turnover and efficiency. We do this without disrupting the logistics processes on the ground floor.

In that found space, we install a high-end customised floor (mezzanine), which can make a significant difference. This floor is designed by us to carry heavy loads, think 2,000kg/m2 and is usually a single deck floor with limited bracing. This means there is no cross bracing between the uprights, maintaining mobility at ground level. The challenge lies in accurately calculating the stability in combination with the required load-bearing capacity, as the storey floor is often equipped with heavy goods.

As indicated earlier, it is essential that logistics processes can continue uninterrupted. Therefore, the column grid should be arranged so that, for example, forklift trucks can continue to move freely. The column grid refers to where the columns are located on the ground floor.

“The key is mobility and efficiency”

Investment

If moving is not an option, the existing space needs to be optimised, which often involves high investment costs. In many cases, this investment pays for itself quickly through the increase in space, speed and turnover.

We prepare a budget for our partner, which he can compare with the cost of moving or a new-build DC together with the end user. Given the customisation, we have to assess financially and technically whether the project is feasible. We look beyond just the cost of the floor. The end-user also has costs for installing the racking. Based on that extra data, we can make a quick and effective calculation and shift gears.

Challenges

It happens that the end user’s DC is located in an earthquake zone. We then have to take this into account when designing the structure. The span then often needs to be limited to maintain load-bearing capacity. At the same time, the columns of the storey floor may need to follow the pattern of the piles of the ground floor. This must then be connected to each other and results in a structure that is fully dimensioned.

“This is a non-standard floor: each design is customised, tailored to the situation. That is our specialisation”

Alignment and cooperation

After surveying the location and our proposal, we discuss the budget with our partner. The end user ultimately decides whether to move or optimise the space in the existing premises. Cooperation with our partner is very important at this stage. For example, he asks the end-user the question: how much turnover do you get from this DC? What percentage do you want to grow? This is how we walk through this process together. Once our partner agrees to our proposal, we start enginering. In high-end custom projects like this, we work directly in 3D, so the project is quickly and clearly understood.

“Cooperation with our customer is very important”

Examples

An example where we created extra space in height is at a large distribution centre of a non-food discount store chain. Behind the loading docks, where there was a lot of mobility due to loading and unloading, we installed a mezzanine for the storage of assembly materials. This bespoke floor was designed to carry goods without disrupting the logistics processes on the ground floor – a high-end, bespoke solution.

Another example is a mezzanine on which robotisation was applied. As a result, this floor had a load of some 2,000 kg/m2. While under the mezzanine employees work and forklift trucks drive, above, on the floor, some 10,000 articles are continuously processed by robots. The employees below the floor do not notice any of this.

Conclusion

Through innovative solutions and customised constructions, we help end-users, through our partner, maximise their storage capacity without compromising on mobility or efficiency. Thus, we support end-users in their growth without disrupting logistical processes.

Do you also want to optimise your storage space? Then contact one of our engineers. We can then discuss your specific options. Call us directly: +31793610663