Various SKU Storage Case Study

Products: Selective Rack and Cantilever Rack
Services: Design, Engineering and Installation


A hardware supplier was opening two new distribution centers: a 410,000 sq. ft. facility in Ohio and 290,000 sq. ft. facility in California. The desired completion dates of the material handling system for each distribution center were close, and therefore each project had to be coordinated simultaneously.

Additionally, the material handling systems needed to accommodate the company’s 13,000 SKUs, which varied significantly in size, shape, and weight.


REB was chosen as the provider of both material handling systems. It was ideal for the company to work with one provider for both systems, and REB has the capabilities to accommodate this.

REB had to thoroughly analyze the SKU characteristics to ensure the racking was designed to hold the required capacities. By separating the SKU’s into product groups REB was able to properly design the racking to accommodate all items that could be stored throughout the DCs. Below are a few of the unique storage solutions that REB implemented:

  • To accommodate for storage of long, thin, light items such as plastic sheets, REB designed tall bays with horizontal rods of electrical conduit to act as barriers to allow the plastic sheets to be stored vertically, providing increased density compared to storing the sheets flat.

Non-Standard Pallet Rack Configurations

  • The company also required storage of long, thin, heavy items such as sheet metal. Because of the increased weight of the sheet metal compared to the plastic sheets, it was determined that they had to be stored flat. In order to still provide high density storage of these items, REB incorporated rows of beams with tight profiles of 6”.

Non-Standard Pallet Rack Configurations

  • For tall or bulky items that can be placed on ground level, a unique barrier was designed to prevent products from rubbing against another.

Non-Standard Pallet Rack Configurations

Once the design was finalized, REB hired all subcontractors, assisted in obtaining all permits for the material handling system, and oversaw the installation process. Because of the large and detailed scope of work needed, REB provided an on-site project manager for both locations. The REB project manager remained on-site for the duration of each project, acting as a go-to person for the customer whenever needed and ensured that the project ran smoothly.


REB designed a layout that enables this company to store all 13,000 SKUs, taking into account the variety of shapes and sizes to maintain high storage density and selectivity. The higher selectivity allows for easier product picking, expediting the order fulfillment process.

The project was completed on-time and within budget. The video provided below outlines the installation process for the Ohio-based distribution center.

Opening A New Distribution Center?

We know expanding operations can be an overwhelming process. If you are expanding into a new distribution center, REB Storage Systems International can help answer any questions you may have regarding the design and implementation of a new material handling system or the installation process. For more information or to get in touch with one of our industry experts, fill out the ‘Submit Your Inquiry’ form.

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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

“REB is by far my favorite vendor, the customer service and dedication to making sure every order is complete and on time. Fantastic communication, and an absolute pleasure to work with.”

Gary Rothschild

Epko Industries

“First time customer and REB provided excellent service and competitive pricing. Would use them again.”

Elliot Sneen

Cabernet Corporation

“Great customer service with an accurate storage system!”

Richard Steed

Pacific Storage Company

“We have used REB Storage Systems for a number of years and will continue to do so in the years to come. Their entire staff are wonderful to work with and provide a seamless installation from beginning to end. Their focus to detail and quality installation has been a valuable resource to our company.”

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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