A Melbourne-based auto parts supplier transforms its overcrowded warehouse into a scalable, efficient space with custom racking and mezzanine solutions, reducing fulfilment times and improving safety.
When a Melbourne-based auto parts distributor found themselves struggling with a warehouse that was rapidly becoming overcrowded, their main concern wasn’t just about adding more racks and shelves. The growth in their operations had simply outpaced their existing setup, which was cluttered with outdated pallet racking, makeshift shelving units, and stock scattered all over the place—literally every available corner. Honestly, this disorganization wasn’t just wasting precious floor space; it was also slowing down their picking process, which led to longer order fulfillment times and more mistakes during handling. They needed something more advanced, scalable, and tailored specifically to handle the unique demands of their auto parts inventory.
Erect-A-Rack stepped in to conduct a full site assessment, taking measurements of the warehouse and observing daily operations. This thorough analysis informed a custom solution—combining selective pallet racking, long span shelving, and a newly installed mezzanine floor. The redesign included wider aisles for safer forklift access and taller racks to maximize vertical space utilization. By dividing the space into logical zones based on SKU velocity, high-turnover items were placed within easy reach, while bulk stock was stored higher up. The mezzanine floor added approximately 40% more usable storage area without expanding the footprint of the warehouse. This significant increase allowed room for growth and more efficient space management.
The results were immediately evident. Fulfillment times decreased by around 25%, stock visibility improved, and staff moved more efficiently within the space. The new layout also enhanced safety by clearly separating pedestrian pathways from forklift routes and removing clutter that previously hampered operations. Importantly, the storage layout was designed with scalability in mind, enabling future adaptations as the company's product lines expanded.
This Melbourne case exemplifies how custom-designed warehouse solutions can drive substantial improvements in space efficiency and operational performance. Modular systems, such as mezzanine floors supported by heavy-duty pallet racks or long span shelving, are increasingly popular because they make vertical space more accessible, are quick to install, and can often be reconfigured to meet evolving needs. For instance, companies like Avanta UK have implemented large fire-rated mezzanine floors spanning hundreds of square metres, complemented by adjustable pallet racking and mesh-decked shelving, demonstrating the versatility and scalability of these solutions for industrial warehouses.
Other providers, such as T Racking and Stow Racking, offer modular mezzanine systems like Mezza-stow®, which integrate with existing pallet racking frameworks and support load capacities from 350 to 800 kg per square metre. These systems facilitate increased storage density while allowing flexibility for future modifications. Additionally, brands like Aceally Racking and YuRacking provide mezzanine solutions featuring various flooring options and safety accessories, making them suitable for high-volume, multi-category storage environments.
Different types of mezzanine floors are available depending on operational needs. Shelving-supported mezzanines are often more affordable, especially for smaller items, though they may be less adaptable for reconfiguration. Structural mezzanines, however, optimize available floor space and offer greater flexibility, making them suitable for expanding or changing inventory types over time. These solutions are specially designed to maximize vertical storage potential, which is increasingly valuable in fast-moving industries like automotive parts distribution.
Overall, the Melbourne distributor’s experience with Erect-A-Rack highlights how tailored, modular warehouse upgrades can substantially enhance storage capacity and operational efficiency. By intelligently utilizing vertical space, establishing logical zones, and enhancing safety, these solutions support sustainable growth in a competitive landscape. For auto parts suppliers and similar businesses, adopting such custom racking and mezzanine solutions is a strategic move to boost productivity, improve inventory management, and position themselves effectively for future expansion.
Source: Noah Wire Services