To reclaim valuable floor space, a large manufacturer partnered with Shelf Master and WPSS to install a 38-foot High Bay Shelving system. Utilizing Deluxe Industrial Storage, this solution optimized vertical space for slow-moving parts inventory, allowing for efficient access via wire-guided order pickers.
The Challenge: Reclaiming Floor Space from Slow-Moving Parts
A large manufacturing company was facing a critical space shortage. Their facility featured soaring 40-foot ceilings, but they were failing to utilize the “air rights” of the building. Instead, slower-moving parts (SKUs) were occupying valuable floor space, cluttering the active manufacturing area.
Key Issues:
- Wasted Vertical Space: The facility had 40 feet of clearance, but traditional storage methods left the upper volume empty.
- Inefficient Footprint: Slow-moving inventory was consuming floor space better suited for high-velocity production and storage.
- Structural Demands: Any vertical solution had to be exceptionally rigid to reach extreme heights without compromising safety, especially in a seismically active region like California.
The Solution: 38-Foot High Bay Deluxe Industrial Shelving
The manufacturer turned to Shelf Master of Anaheim, CA, to engineer a solution. Recognizing the need for extreme height and rigidity, Shelf Master selected Western Pacific Storage Solutions (WPSS) Deluxe Industrial Shelving.
Engineered for Altitude
- Extreme Height: The system was designed to rise 38 feet into the air, utilizing nearly every inch of available vertical space.
- Box Post Rigidity: The system utilized WPSS Deluxe Box Posts, which provide superior strength. Crucially, these posts allowed the structure to reach 38 feet without splicing, ensuring maximum structural integrity and seismic compliance.
- High Capacity: The installation provided 1,200 shelves, creating a massive density of storage locations within a compact footprint.
Efficient Access
To access inventory at such heights, the system was designed for use with a man-aboard order picker truck.
- Wire-Guided Safety: The aisle is wire-guided, allowing the operator to travel safely and efficiently to any pick location within the 38-foot structure.
- Direct Picking: Operators can pick orders directly from the shelves at any level, eliminating the need to bring pallets down to the floor.
Results: Optimized Cube and Expanded Floor Space
The installation of the High Bay Shelving system transformed the facility’s storage capabilities.
| Outcome | Benefit to Client |
| Optimized Cube | By building up to 38 feet, the manufacturer fully utilized the facility’s volume, turning wasted air into valuable storage. |
| Reclaimed Floor Space | Moving slow SKUs into the high-bay system freed up the ground floor for faster-moving inventory and production activities. |
| Seismic Safety | The splice-free box post design provided a rigid, code-compliant structure capable of withstanding seismic forces. |
| Operational Efficiency | The integration of order pickers allows for safe, rapid retrieval of parts even at the highest levels. |
By leveraging the height of Deluxe Industrial Storage, the manufacturer successfully systematized their inventory and maximized their facility’s potential. 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.