Selective Pallet Rack Pick Module for eCommerce Distribution – A Case Study

REB designed, installed, and project managed a scalable pick module that could be expanded in the future without requiring the company to expand the facility itself.

Solution at a Glance

A rapidly growing eCommerce retailer partnered with REB to outfit a new distribution center with a pick module. The pick module is comprised of selective pallet racking that improved inventory selectivity, increased storage density, and allows for future expansion as the company grows.

• Services Provided: Design, Installation, Project Management
• Products Provided: Selective Rack, Wire Decking
• Industry: eCommerce
• Location: Chicago, IL
• Number of Projects REB Completed for Customer: 1

Concern: Outfitting a New Facility with a Scalable Solution

Due to order volume increase, an ecommerce company’s existing warehouse no longer could support both its current order volume and the projected growth. The company used 18” back-to-back shelving units to store cartons of products. They needed to relocate their operations into a larger distribution center with an upgraded storage solution to increase picking speed and accuracy.

This company stocks a large number of SKUs and requires that they are easily accessible for their piece-picking process. This requires a highly selective storage system that allows their employees to quickly locate and pick the individual products.

Solution: A Scalable Selective Pallet Rack Pick Module Designed for High-Volume Piece Picking

Pick Module Layout Optimization

Pick modules are designed so that inventory is stored in highly accessible picking locations that support the picking process of the company. Selective pallet racking is highly customizable, allowing each beam level to be set to fit the product that is stored on it.

REB proposed using 36” deep x 96” wide pallet rack instead of the 18” deep x 48” wide shelving. Configuring the system this way requires less material overall versus the shelving and eliminates the need for a flue space that is required in-between the back-to-back rows of shelving. This allows them to store more product in the same space. It also gives them the flexibility to use the full depth of 36″ should their product size change over time.

Custom Wire Decking Designed for Safety and Flexibility

Wire decking was installed on all shelf beam levels across the pick module.

Due to the 36” deep racking not requiring the flue space that the back-to-back 18” rows required, the wire decking keeps each level of the system over 50% open. This helps keep the system fire code compliant across all fire codes.

REB also customized portions of the wire decking so it could be installed around building columns and other obstructions. Rather than leaving the space unutilized, these modifications allowed the racking and wire decking to extend closer to the building structure, improving the storage density.

Future Catwalk Expansion

REB’s design accounts for the customer’s immediate storage needs as well as future vertical expansion. Since the customer was projecting continued growth over the next three years, the system is designed to support a catwalk level that would allow them to double their storage capacity and density.

During the initial design process, REB performed preliminary structural calculations to determine the minimum component requirements necessary to support a catwalk level. Planning ahead allowed the design to be prepared and stamped for future permitting and installation while also providing the customer with a projected bill of materials for the second phase.

Designing the system for future expansion minimizes disruption when the second phase is implemented and allows the customer to plan future investments with greater confidence.

Project Management

REB coordinated multiple aspects of this project to ensure the storage system supported both immediate operational needs and future expansion. This includes:

By considering future growth during the initial design process, REB delivered a warehouse solution that could evolve without requiring a complete redesign.

Outcome: Improved Piece Picking Designed for Future Growth

By partnering with REB, the company successfully outfitted their new distribution center with a storage system that satisfies their current storage needs and able to grow with the company.

Faster, More Accurate Order Picking

Clearly defined storage locations and direct access to individual SKUs make it easier for warehouse employees to locate and retrieve products during piece picking. This organization helps reduce the time spent searching for inventory while supporting more accurate order fulfillment as the company’s order volume increases.

High Selectivity System

The selective pallet rack provides direct access to every shelf level, allowing employees to retrieve individual items efficiently while supporting a wide variety of SKUs.

Greater Storage Capacity Within the Existing Footprint

The optimized 36” deep rack configuration allows increased storage density without sacrificing the accessibility needed for piece picking. Eliminating the flue space that would have been required between back-to-back 18” rack rows also allows more of the available warehouse footprint to be used for storage.

Cost Savings

Using 36” deep sections of racking instead of two back-to-back 18” sections reduced the amount of racking materials required to make this system, while also maintaining the storage capacity the customer desired.

Scalable Solution

By engineering the structure to accommodate a future catwalk, the customer can expand storage capacity with minimal disruption to the existing operations.

Planning a Storage System for Your Piece Picking Operation?

Whether you’re expanding an eCommerce distribution center, increasing SKU counts, or planning for future requirements, REB Storage Systems designs scalable pick module solutions that improve warehouse efficiency.

Contact REB to discuss your operational goals and learn how a custom pick module can support your current operation while providing flexibility for future growth.

We’d appreciate the opportunity to help you further, whether that be more information or a quote. Fill out the contact form on this page or call us at (800) 252-5955 to get in touch with a REB representative.