A cramped Texas food distribution center avoided costly expansion by installing a work platform to house Deluxe Industrial Shelving above and below. This solution doubled usable space, decluttered inventory, and saved the company over 30% compared to new construction.
The Challenge: Overcrowding and Inefficient Throughput
A Texas food distribution center, handling a vast array of dairy, beverage, confectionery, and foodservice goods, was operating at capacity. The facility was so overcrowded that employees struggled to execute their jobs efficiently.
Key Issues:
- Slow Operations: Inventory management, restocking, and order fulfillment were significantly slower than benchmarks.
- Cramped Conditions: The lack of space created clutter, making it difficult to access products and move through the warehouse.
- High Expansion Costs: The company considered buying a bigger building or expanding outward, but the costs were prohibitive.
Management knew they needed a warehouse revamp to declutter and optimize throughput without the massive expense of a new facility.
The Solution: Deluxe Industrial Shelving System
Instead of expanding outward, the company chose to utilize its vertical space. Partnering with Western Pacific Storage Solutions (WPSS), they implemented a comprehensive solution that integrated three systems into one efficient structure.
Doubling Space with Two Levels of Shelving
The core of the solution was the installation of Deluxe Industrial Shelving (formerly Pacific shelving) on both the upper and lower decks of a newly installed work platform.
- Systematized Storage: The shelving units were installed on two levels, effectively doubling the square footage available for inventory storage.
- Heavy-Duty Construction: Formed of heavy-gauge steel, the Deluxe shelving provided maximum weight-bearing capacities for heavy food products.
- Flexible Design: The shelf clip design allowed for easy installation and repositioning, enabling the team to customize the workspace for restocking and fulfillment needs.
Integrated Access
The system was supported by a 50’ x 35’ work platform with galvanized bar grating for ventilation and durability. Access to the second level of shelving was provided by IBC-compliant stairs, ensuring safe and convenient movement for employees.
Results: 30% Savings and Streamlined Operations
The decision to build up rather than out paid off immediately.
| Outcome | Benefit to Client |
| Cost Savings | Saved 30% or more compared to the cost of buying a new building or expanding the current footprint. |
| Doubled Capacity | Created two floors of storage where there was previously one, significantly increasing usable square footage. |
| Decluttered Inventory | The organized Deluxe Industrial Shelving system cleared the floor, allowing for faster, safer movement of goods. |
| Optimized Throughput | Streamlined the pick, pack, and ship process, resolving the operational bottlenecks that had plagued the facility. |
By leveraging Deluxe Industrial Shelving on two levels, the distribution center transformed its operations, proving that the right storage solution can unlock massive value within an existing footprint. Ready to work on your next project? Big or small, WPSS has experts ready to assist! We provide layout guidance, spec sheets, and recommend best-practice clearances to ensure an efficient and space saving design. Contact us today for a quote.