Racking Relationship – A Case Study

Solution at a Glance

An injection molding manufacturer partnered with REB over multiple warehouse projects spanning nearly two decades. REB provided rack removal, warehouse redesign, used and new pallet rack, installation, and project management as the company’s storage needs evolved.

Concern: Supporting Long-Term Warehouse Growth Without Replacing Existing Storage Assets

An injection molding manufacturer was experiencing increased customer demand and changing warehouse storage requirements.

Initially, the company worked with REB to remove and sell pallet rack from an 80,000-square-foot building it was vacating. As the business expanded over the following years, the company’s storage needs shifted from reducing warehouse assets to increasing storage capacity.

Rather than treating each project independently, the customer required a storage partner to evaluate existing equipment, incorporate previously installed rack when practical, and design new warehouse layouts that support future growth. This approach allowed the company to continue expanding while maximizing previous investments in warehouse infrastructure.

Solution: Flexible Warehouse Design That Evolved with the Business

Following the initial rack removal project, the manufacturer continued working with REB as warehouse requirements changed.

Over the next decade, REB completed multiple warehouse modifications, including the installation of additional racking, teardowns, relocations, and reconfigurations. Rather than requiring complete warehouse replacements, each project was designed to build upon previous installations whenever practical.

This flexible approach allowed their warehouse to evolve alongside the business.

Double-Deep Selective Rack for Increased Storage Density

For the first project, the company’s goal was to utilize half of their warehouse for the storage of their completed products. This goal meant that the customer needed a high-density storage solution so they could store all of their products in half the space.

To increase pallet density, REB designed and installed seven rows of double-deep selective pallet rack using 138-inch long beams, 42-inch-deep frames, and 18-foot-tall uprights. Most bays had 4 beam levels that each provide 3 pallet positions worth of storage. In total this solution provided the company with 1,410 pallet positions of storage.

Double-deep pallet rack stores pallets two positions deep rather than one, increasing storage density compared to conventional selective pallet rack while still providing relatively direct pallet access. This makes the system well suited for manufacturers that store multiple pallets of the same SKU while seeking to maximize available warehouse cube.

The new system helped the company utilize the remaining warehouse space more efficiently after reducing its occupied footprint.

Warehouse Redesign to Maximize Existing Assets

Two years later, as the company continued to experience increased demand they decided to use the remaining, unutilized, space within their warehouse. Once again, they worked with REB to assess what the best option is for their space.

After evaluating the manufacturer’s existing system, available space, materials to be stored, and picking practices, REB developed a new warehouse layout that incorporated previously installed equipment, rather than designing an entirely new storage system.

The updated racking layout included 380 bays of racking. REB suggested rotating portions of the existing rack system to improve overall space utilization and to maximize storage capacity.

Project Management

Throughout this partnership, REB provided more than just rack installations. REB served as an ongoing systems integration partner by coordinating multiple phases of warehouse modifications over many years.

REB’s involvement included:

Managing each project as part of a long-term solution allowed the company to continually adjust and optimize their warehouse layout without starting from scratch whenever their storage needs changed.

Outcome: A Warehouse Storage System That Adapted to Decades of Growth

By partnering with REB across 17 projects spanning nearly two decades, the manufacturer was able to continually adjust its warehouse storage system as its business and space requirements changed. Instead of replacing its storage infrastructure with each new phase of growth, the company could build upon, relocate, and reconfigure existing equipment while adding new capacity when needed.

Increased Storage Capacity as the Business Grew

REB helped the manufacturer expand its storage capacity as demand increased, including a double-deep selective rack system that provided 1,410 pallet positions and a subsequent warehouse redesign incorporating 380 bays of racking. This allowed the company to increase storage capacity within its existing facilities rather than requiring additional warehouse space for every stage of growth.

Improved Space Utilization

When the manufacturer began using previously unutilized areas of its facility, REB redesigned the warehouse layout around the space and equipment already available. Rotating portions of the existing rack system helped improve the overall layout and make more effective use of the facility’s available footprint.

Existing Equipment Continued to Provide Value

Rather than treating previously installed rack as obsolete whenever the warehouse layout changed, REB evaluated how existing equipment could be reused, relocated, or reconfigured. This allowed the manufacturer to extend the value of its existing storage investment while adding new equipment where necessary.

Flexible Growth Strategy

The manufacturer’s storage requirements changed significantly over the course of the relationship. From removing and selling rack to adding storage capacity as the business expanded, REB supported each stage with solutions that evolved alongside the company’s operational needs.

Long-Term Project Continuity

With 17 projects completed over nearly two decades (and counting), the manufacturer relies on one partner for warehouse assessment, design, rack removal, reconfiguration, installation, and permitting support. Having continuity for every projects provides a simplified, consistent growth approach.

Contact REB About Your Warehouse Expansion Project

Warehouse requirements often change as businesses grow and adapt. Whether you need to expand an existing pallet rack system, relocate racking, incorporate used racking, or redesign your warehouse for overall greater efficiency, REB Storage Systems provides the design and project management expertise to help your facility adapt.

Contact REB to discuss your warehouse expansion goals and develop a storage solution designed around your facility, inventory profile, and long-term growth plans. Fill out the contact form on this page or call us at (800) 252-5955 to get in touch with a REB representative.