At REB Storage Systems International, we understand the complex demands of modern retail warehousing and distribution centers. Whether you’re fulfilling e-commerce, local delivery, or wholesale orders, your facility needs storage and material handling solutions that maximize space, improve throughput, and reduce labor costs.

Our tailored layouts can combine pallet rack, conveyors, pick modules, and automation, all designed to accelerate your operation and deliver results you can measure.

Read further to learn more about REB’s retail warehousing and distribution solutions.

Why Retail Clients Partner with REB

Customized material handling design: We assess SKU profiles, pick methods, turnover rates, and growth plans to design the best solution for your space and workflow. Our designers craft a solution that balances selectivity, density, and throughput for your specific operation.

End-to-end project management: Design, procurement, permitting support, subcontractor oversight, and installation are all managed by REB experts. You’ll have one point of contact throughout each phase of your project.

Scalable systems built for growth: REB considers the long-term partnership with clients. We want to provide you with solutions that are optimal for current operations and as you grow.

Retail Warehousing and Distribution Solutions – What We Offer

Multilevel Pick Modules and Conveyor Integration

Retail operations with high SKU counts and rapid pick/pack cycles benefit from multilevel pick modules. These systems maximize vertical space and typically integrate conveyors to move products efficiently from picking zones to packing and shipping areas.  — reducing travel time, lowering labor costs, and improving throughput dramatically.

Key Benefits of a Multilevel Pick Module + Conveyors for Retail Distribution

• Increases storage density: The multiple levels of this type of system utilizes the vertical space of a distribution center. Tailoring each bay (the space between beam levels) is tailored to product sizes will further increase density.
• Increases pick rates: Conveyors reduces required travel time for pickers, allowing them to pick more orders.
• Lowers labor costs: Automation decreases the requirement for employees to be involved in every step of the distribution process. 
• Improves throughput: Adding automation via conveyors decreases the time it takes pickers to pick items and transport them to their distribution location.  

High Density Racking Systems

There are several types of racking, each that is ideal for certain types of inventory and flow requirements. Therefore, strategic placement of different types of racking within a pick module is beneficial.

Selective Rack

Selective rack is the most widely used racking system in distribution centers due to its versatility in accommodating a range of SKU sizes and shapes. Bays can be customized for different inventory needs, and the system can serve both palletized storage and hand-picking operations as needed within a pick module. Because of this, it provides high selectivity with moderate density.

Push Back Rack and Pallet Flow Rack

Push back rack and pallet flow rack are gravity systems that provide higher storage density than selective rack by storing multiple pallets deep in each lane. Pallet flow rack follows a first-in, first-out (FIFO) flow, ideal for date-sensitive products, while push back rack uses a last-in, first-out (LIFO) flow.

These systems are ideal for storing multiple pallets of the same SKU, since each SKU can be stored in designated lanes.

Carton Flow Rack

Carton flow rack uses inclined, gravity-fed shelves to keep cartons or bins moving toward the picker automatically. This improves visibility and access compared to traditional static racks. It’s particularly useful for high volume hand picking and can be integrated into multilevel systems or catwalks to increase throughput.

Drive-In and Drive-Through Rack

Drive-in and drive-through racking eliminate cross aisles by allowing forklifts to enter the rack structure. This significantly increases storage density. However, selectivity is decreased.

Drive-in and drive-through rack is ideal for high-density storage of homogeneous pallets or overflow inventory.

Cantilever Rack

Cantilever rack is specialized for storing long or irregularly shaped items such as lumber, piping, or furniture that don’t fit well on standard pallet racks. With horizontal arms supporting products from a central column, it offers better accessibility and selectivity for these hard-to-store goods within a pick module.

Key Benefits of High-Density Racking Systems for Retail Distribution

• Versatility: The range of racking systems provides options that are ideal for any operation. Often, multiple types of racking systems are used in the same distribution center to maximize productivity.
• Optimal density and selectivity: By tailoring racking systems to SKU characteristics and picking needs, the right amount of density and selectivity to optimize a retail distribution operation can be achieved.
• High throughput:

Vertical Lift Modules

A vertical lift module (VLM) is an automated storage solution that significantly boosts storage density, often by as much as 90% compared to traditional pallet racking. Its ability to accommodate items of varying sizes while maximizing vertical space makes it an excellent choice for retail storage and distribution.

A VLM consists of an enclosed system of vertically stacked trays with an extractor positioned in the center. With the push of a button or a barcode scan, the system automatically retrieves and delivers the required tray to an accessible pick window.

Key Benefits of a Vertical Lift Module for Retail Distribution

• Reduced labor costs: By delivering items directly to the operator, travel and search time commonly associated with a rack system is drastically reduced. This allows the operator to spend more time picking, increasing overall productivity.
• Increased picking speed: VLMs can increase productivity due to the machine locating and presenting each item. This feature eliminates ‘dwell time’ the picker may spend searching an aisle. 
• Eliminates dwell time: Less time is spent in the aisle pulling the product. The machine presents the item to you upon request.
• Saves up to 90% of the footprint: By consolidating a racking or shelving system into a VLM, you will free up to 90% of the current floor space being used to store.
• Eliminates shrinkage: VLMs track all activity. It knows who used it last, what they did, and so much more. There are reports that can be generated to see this information.
• Improved ergonomics: VLMs compensate for the height of the picker. The picker’s preferred picking height is specified in their profile setup in the system and recognized upon employee sign in.

 

Pick Carts

For efficient movement of items to and from the backroom, REB provides retailers with a range of pick carts. With numerous configurations and features available, it’s beneficial to work with a material handling specialist, such as REB, who can evaluate your needs and identify the pick cart best suited to your operation.

Other Products for Retail Distribution Centers

REB is proud to consider ourselves a “one stop shop” for our retail clients. Additional products REB offers to support a distribution center include:

• Dock bumpers and dock seals
• Bins, fans, pallet jacks, ladders, cranes, and other material handling equipment
• Pallet rack protection
• Mezzanines

Retail Warehousing and Distribution Case Study Highlights

1. Automotive Parts Wholesaler — Multilevel Pick Module with Conveyors

• • REB designed a multilevel pick module integrated with conveyor systems to support high-volume order fulfillment and distribution to multiple locations.
  • This solution improved throughput, increased picking efficiency, reduced picker travel time, and created a more controlled, scalable material flow throughout the facility.
  • Click to read the full case study.

2. Distribution Center — Selective, Drive-In, Push Back Rack + Conveyor Integration

• • To support a complex SKU mix and high pallet volume, REB implemented a combination of selective rack, drive-in rack, push back rack, and conveyor.
  • This integrated solution significantly increased storage density, created better product organization, reduced handling time, and improved overall operational efficiency.
  • Click to read the full case study.

3. Apparel Fulfillment Operation — Custom Storage Build Under Tight Deadline

• • Faced with rapid timeline requirements, REB engineered and installed a storage and material handling solution that included selective pallet rack, shelving, and customized picking equipment.
  • The facility gained structured SKU organization, improved order picking processes, and the ability to meet growing fulfillment demand without operational disruption.
  • Click to read the full case study.

4. Distribution Center — Pick Module Designed for Future Expansion

• • REB designed a pick module layout focused on improving picking efficiency while providing the flexibility to scale.
  • The design created a more efficient picking flow, maximized vertical cube usage, reduced congestion, and ensured the operation could grow its fulfillment capacity as volumes increased.
  • Click to read the full case study.

5. Warehouse with Diverse SKU Requirements — Structured Storage Strategy

• • To support a large variety of product sizes and storage needs, REB developed a system using selective rack and specialty storage solutions to accommodate both palletized and case-pick items.
  • This approach delivered improved SKU accessibility, increased organization, and better utilization of available warehouse space.
  • Click to read the full case study.

6. Facility with Picking Process Challenges — Pick Cart Redesign

• • REB provided a beauty and personal care retailer with custom pick carts that addressed issues with their old pick carts.
  • The revised pick carts decreased picking error rates, increased pick rates, and increased safety.
  • Click to read the full case study.

7. High Density Storage Need — 2-Deep Drive-In Racking Implementation

• • For a warehouse requiring dense pallet storage, REB installed a 2-deep drive-in rack system to maximize available cubic space.
  • This solution increased storage density, improved pallet organization, reduced wasted aisle space, and supported high-volume inventory storage needs.
  • Click to read the full case study.

Ready to Optimize Your Retail Distribution Center?

From initial design to installation and beyond, REB delivers retail warehousing and distribution solutions that accelerate throughput, reduce costs, and scale with your business.

Contact REB to discuss your project, request a quote, or learn how we can help you elevate your distribution operations. Fill in the contact form on this page or call us at (800) 252-5955 to get in touch with a REB representative.