PROJECT HIGHLIGHTS
| Location | Challenge | Facility Size | Storage Capacity | Racking System Solution | Timeline | Services Provided |
|---|---|---|---|---|---|---|
| Windsor, ON | Warehouse Expansion | 5,200 sq. ft. | 72 Pallet Positions, 30 Industrial Reel Holders, 3 Bays of Vertical Storage | Light Duty Pallet Racking, M-Bar Dividers, Reel Storage | 8 week production, 3 day install | Design, Installation |
THE PROBLEM
Our existing customer, an electrical wholesaler, was looking to implement a warehouse expansion. They identified the need for a new warehouse location to better support customers and expand operations. However, opening a second facility introduced a new set of challenges.
The new warehouse would be located approximately 3.5 hours away from the company’s primary operation. Designing an entirely new warehouse layout could introduce unnecessary complexity, increase training requirements, and create inefficiencies during startup.
With a new facility needing to become operational quickly, our customer required a warehouse storage solution that would reduce risk, simplify onboarding, and allow the team to leverage the operational knowledge they had already developed over years of experience.
THE SOLUTION
To help our customer scale efficiently, Concept Storage Solutions proposed a straightforward but highly effective approach: replicate the layout of their existing warehouse.
Rather than designing an entirely new storage configuration, the team recreated the proven warehouse layout already being used successfully at the company’s primary facility.
By mirroring the existing operation, they were able to maintain consistency across both locations while minimizing implementation risk. The warehouse expansion was equipped using:
- 72 pallet positions utilizing light-duty pallet racking
- 30 reel storage positions for wire and cable inventory
- 3 dedicated bays with M-Bar dividers for vertical product storage
- Wire mesh decking for enhanced product support and safety
Production was 8 weeks long to create the custom light duty pallet racking system, M-bar dividers, and reel holders. After the equipment was delivered to the new location, it was installed by our crew in 3 days time.
The result was a familiar operating environment that employees already understood, allowing the company to transition into the new facility with confidence.
THE RESULTS
- 72 pallet positions installed for inventory storage
- 30 industrial reel holders incorporated into the layout
- 3 bays of vertical storage created using M-Bar divider systems
- Reduced employee training requirements through a familiar layout
- Improved operational consistency between warehouse locations
- Faster implementation compared to developing an entirely new storage strategy
BENEFITS
PROVEN PERFORMANCE
By duplicating an existing layout for the warehouse expansion, our customer gained a storage solution they already understood and trusted. Employees could immediately leverage existing knowledge, reducing startup challenges and improving efficiency.
EASIER MANAGEMENT
With both facilities operating using the same layout principles, management can more easily coordinate inventory, processes, and future improvements across locations.
SIMPLIFIED MAINTENANCE AND REPAIRS
Because both facilities utilize the same storage systems, future inspections, repairs, and modifications can be managed more efficiently. Consistency across facilities helps ensure maintenance standards remain aligned while reducing complexity for service providers.
SYSTEMS & SERVICES USED
Selective Pallet Racking
M-Bar Dividers
Pallet Racking Accessories
FAQ
The number of pallet positions depends on ceiling height, product dimensions, aisle requirements, and the type of pallet racking system used. With proper warehouse design, even smaller facilities can achieve significant storage capacity while maintaining accessibility.
M-Bar dividers are commonly used to create organized vertical storage areas for long or oversized products. They help improve product accessibility while maximizing the use of available warehouse space.
For companies looking to do a warehouse expansion, creating a proven warehouse layout can often be more valuable than starting from scratch.
A replicated warehouse design allows teams to:
- Maintain consistent inventory locations and storage practices
- Reduce training requirements for new employees
- Simplify inventory management across multiple locations
- Implement operational improvements at both facilities simultaneously
- Reduce the risk associated with launching a new warehouse operation
It depends on the operation. If an existing warehouse layout is performing well, replicating that design can save time and reduce startup challenges. However, changing inventory requirements, building dimensions, or operational needs may require modifications to the original layout.
