Smart storage solutions to boost capacity

Struggling for warehouse space? You may not need to move

When a warehouse feels full, many businesses consider expanding by leasing or buying new space, or even relocating. However, sourcing suitable premises, securing funding, and managing the disruption can be costly and stressful. Instead, rethinking how your current space is used can be a smarter, faster, and more cost-effective solution.

The smart alternative: Optimise existing space

There is often untapped potential within your current facility. By improving layout, racking configurations, and stock profiling, you can unlock extra capacity without increasing your footprint. Understanding how your space is currently used and how stock flows through the warehouse is the essential first step.

Practical ways to boost capacity

One key issue is poor “slotting”, where items are placed in unsuitable locations. Effective slotting involves grouping products by size, weight, demand, and picking frequency to improve space usage and reduce travel time for operatives. Using standard pallet sizes and modular storage bins also helps eliminate wasted space.

Check that your storage systems are suited to your stock profiles. Consider the following enhancements:

•Make better use of vertical space by installing taller racking and adding mezzanine floors.

•Replace standard aisles with narrow or very narrow aisle (VNA) racking to increase storage density.

•Introduce automation such as automated storage and retrieval systems (AS/RS), vertical lift modules (VLMs), and carousel systems to compact storage without compromising access.

•Implement cross-docking to move goods directly from receiving to shipping, reducing storage needs and congestion in high-turnover zones.

Efficient stockholding

Excess stock takes up valuable space and ties up capital. While it may seem prudent to over-purchase to avoid shortages, this can result in expired, obsolete, or seasonal items remaining on shelves. Optimising stock levels involves finding the right balance between service levels and holding costs. Improved forecasting and supply chain planning are key to maintaining that balance.

The benefits of optimising your current warehouse

1. Increase storage and efficiency

Smart changes to layout and the use of vertical storage allow you to store more goods without losing accessibility. Improved slotting and better use of space reduces congestion, streamlines picking, and increases order accuracy while shortening cycle times.

2. Lower operating costs

A more efficient warehouse reduces labour costs, stock damage, and loss. Automation reduces manual handling and improves accuracy. Organised workflows contribute to energy savings and higher overall productivity.

3. Avoid the cost and disruption of moving

Improving the use of your existing facility can delay or eliminate the need for new premises. Relocation is expensive, time-consuming, and disruptive. Getting more from your current space increases return on investment and supports sustainable growth.

Case studies: Success without relocation

High-end perfume distributor

A UK distributor of niche luxury perfume brands engaged The Supply Chain Consulting Group (SCCG) when considering a move due to capacity limits. SCCG redesigned the warehouse layout and introduced dense storage technologies, allowing the business to double its turnover within the same facility. With process improvements and a new warehouse management system, the company avoided a costly relocation.

Beyond the Bean (BtB)

BtB, a Bristol-based manufacturer serving the café bar and foodservice industry, asked SCCG to help increase storage capacity. SCCG provided revised layout drawings, a capital equipment schedule, and recommended a temporary overflow building. These improvements were successfully implemented with continued project support.

We can help you too

The Supply Chain Consulting Group is a UK-based logistics consultancy, specialising in warehouse design and supply chain strategy. With over 700 projects completed in more than 30 countries, we help businesses increase capacity and improve efficiency without the disruption of moving.

Before investing in additional space, contact SCCG to review your current facility. Our experts can help you maximise capacity, streamline operations, and support your growth plans cost-effectively. Contact our warehouse consultants today at 01926 430 883 or email your enquiry to us at info@sccgltd.com.The post Smart storage solutions to boost capacity first appeared on Warehouse & Logistics News.