Pick Module Design Case Study

Project Details:

Location: WI
Facility Size: 190,000 sq. ft.

Products Featured:

Selective Rack – Carton Flow Rack – Pallet Flow Rack – Pick Module


A pool supplies distributor was relocating its distribution center to accommodate growth. The new 190,000 sq. ft. facility required a material handling system to support the high volume of products stored and distributed.


REB was provided with a list of all products as well as material handling methods used. Each of these items was evaluated to develop a storage solution that optimizes the flow of orders.


  • Forklifts are used to transport pallets. Employees then pick individual cases of products for order fulfillment.
  • Because of rapid product turnover, excess pallets of products are taken into the facility.
  • The company predicts substantial growth over the next five years.

Pick Module Design

Based on this, REB engineers developed a layout that includes a forward pick area and a reserve storage area.

Forward Pick

The forward pick area spans 5,700 sq. ft. of the distribution center. For this area, REB implemented a pick module design that integrates multiple rack system types to reduce overall pick time:

Forward Pick

  • 2-deep pallet flow on ground level for easy forklift access 
  • Two levels of carton flow above pallet flow for efficient case picking
  • Five levels of selective rack for product replenishment of the carton and pallet flow

Pick Module Design Floor Plan

The pick module design also accommodates an option for a catwalk level to allow for future vertical expansion.

Reserve StorageReserve Storage

The reserve racking area spans 83,800 sq. ft. of the distribution center and consists of 5 levels of selective pallet rack. This racking is used to store the overflow of items that are to be used for replenishment in the forward pick area.


The company now has designated areas for active picking and static storage. Because the pick module was designed around the company’s unique operation, the flow of orders is optimized. The vertical expansion capability of the pick module will allow the new building to accommodate future growth without expanding its footprint.

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Brian Dubin

All Products Automotive, Inc.

“We have been a customer for over 15 years. REB offers a good selection of products at great prices. They are an excellent source of materials along with suggestions and information on a variety of storage issues."

Bruce Moulton

Harrington Industrial Plastics

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Gary Rothschild

Epko Industries

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Elliot Sneen

Cabernet Corporation

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Pacific Storage Company

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Tom Beckermann

Felling Trailers Inc.

“REB Storage Systems provides a high quality product with the best customer service in the industry, no matter the volume of products we buy.”

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