Faced with the rise of e-commerce, a global retailer transitioned its in-house 3PL operations from inefficient pallet racking to a high-density solution. Partnering with WPSS, they installed High Bay Shelving Pick Modules, doubling storage capacity and significantly improving pick rates by utilizing vertical space and narrowing aisles.
The Challenge: Inefficient Fulfillment in an E-Commerce World
A global retailer realized it was effectively running a massive Third-Party Logistics (3PL) operation within its own enterprise. However, its fulfillment processes were stuck in the past.
Key Issues:
- Outdated Infrastructure: The retailer relied on traditional pallet racking, which is ideal for bulk storage but inefficient for the “each pick” (individual item) fulfillment required by modern e-commerce.
- Wasted Space: Pallet racks require wide aisles for forklifts and limit vertical storage density for small items, resulting in poor utilization of the warehouse cube.
- Operational Lag: Using large equipment to retrieve small items caused order delays, errors, and safety concerns.
To compete in the omnichannel economy, the retailer needed a solution that prioritized denser storage, safer workflows, and faster pick rates.
The Solution: WPSS High Bay Shelving Pick Modules
Recognizing the need for a specialized solution, the retailer partnered with Western Pacific Storage Solutions (WPSS) to transition from pallet racking to Deluxe Industrial Shelving.
Going Vertical with High Bay Shelving
WPSS engineered a system designed specifically for medium-to-slow-moving products:
- High Bay Design: The team installed 190 units of High Bay Shelving, soaring 37 feet into the air. This design reclaimed 24 feet of vertical space that was previously wasted above standard racks.
- Narrower Aisles: Because the new system relies on order pickers rather than forklifts, the retailer could narrow its aisles from 15 feet down to 5 feet. This simple change recovered a massive amount of floor space.
Results: Doubled Capacity and Optimized Flow
The shift to Shelving Pick Modules transformed the retailer’s distribution capabilities.
| Outcome | Benefit to Client |
| Doubled Capacity | By narrowing aisles and utilizing vertical space, the retailer effectively doubled its product storage capacity. |
| Cube Efficiency | The 37-foot high bays maximized the “cube,” turning empty air into valuable storage real estate. |
| Operational Speed | The optimized design significantly enhanced picking speed and accuracy, leading to a follow-up order for an additional 60 units. |
| Cost Savings | With order picking accounting for 55% of operational costs, the move to a specialized pick module delivered substantial long-term savings. |
By adopting High Bay Shelving, this retailer successfully modernized its 3PL operations, proving that the right infrastructure is key to thriving in the age of e-commerce. 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.