When people talk about storage solutions, many people immediately imagine rows of iron structures in a warehouse. But this is perhaps the biggest simplification. In fact, it is always complex: from the analysis of commodity flows and the specifics of the cargo to the choice of the type of racks, their configuration, related equipment and even loading and unloading logistics. A common mistake is to start by purchasing shelving and then try to fit business processes to it. It turns out to be expensive and ineffective.
In my practice, there have been several cases when a client came with a ready-made floor plan and a request to “make shelving like the neighbor’s.” The first question we ask is: what will you store? Pallets with homogeneous products or piece goods of different sizes? What's the turnover? Do you need FIFO (first in first out) or LIFO? Without answers to these questions, any decision will be a step into darkness.
Once we worked with a logistics company that stored auto parts. Initially they wanted classic pallet racks. But when they started sorting out the product range, it turned out that 40% of the goods were long pieces (bumpers, sills). Standard solutions were not suitable here. We had to combine: an area with cantilever racks for long loads and an area with shelf systems for small parts. The key is analysis down to the smallest detail.
Here, by the way, it is important to look not only at current needs, but also at growth plans. We once installed a system for small production, designed for 500 pallet spaces. Within two years they had tripled in size and the storage system had become a bottleneck. We had to completely redesign the warehouse, adding mezzanine structures. Expensive and stop working. Now we always include at least 20-30% reserve for height and load in the project.
Choosing the type of shelving is, of course, the basis. Pallet (frontal, deep, gravity), shelf, console, racks for four-way shuttles - each has its own niche. But the rack itself is just steel. Its effectiveness is determined by everything around it: the floor covering, the marking system, the type of forklifts, even the lighting.
Let me give you an example with beam racks. An excellent solution for long materials, pipes, profiles. But if you have an uneven floor or a low-capacity forklift, all the efficiency is lost. We cooperate with manufacturers who understand this complexity, for example, with the Jusheng plant. (Harbin Jusheng Metal Structures Manufacturing LLC). Their websitehttps://www.jshj.ru- this is not just a catalog, it shows that they think in terms of systems, and do not just sell racks and beams.
The accuracy of installation is especially critical. A difference of a couple of millimeters between the racks can lead to the beam not sitting on the lock, or the loader will catch on the structure. I saw objects where the installation was done by “shabashniks”, saving on the project. The result is constant breakdowns and the risk of collapse. Therefore, it is important for us to work with suppliers who provide the full cycle: from design and production to installation and service, like the same company “Jusheng”, which positions itself as a full-cycle enterprise.
When talking about modern storage solutions, we cannot ignore the topic of automation. But here it is important not to chase fashion. Four-way shuttles are a cool technology, but for 90% of small and medium-sized warehouses they are overkill. But properly designed mezzanine systems or the choice between front-mounted and drive-in shelving can provide a huge increase in efficiency.
We had a project for a pharmaceutical distributor. Strict requirements for shelf life (FIFO), a huge range of products, the need for quick selection. Classic racks did not provide the required speed. Designed a system using gravity pallet racking for fast turnaround and shelf racking with dynamic picking for small batches. Integration with WMS was planned at the equipment design stage. The result is a reduction in selection time by 40%.
But there are pitfalls here too. Automation requires qualified maintenance. If there are no specialists in the city, and the system fails, the entire warehouse will stop. Therefore, we always invite our clients to soberly assess their personnel and financial capabilities. Sometimes it’s better to make something that’s reliable, albeit less “smart.” system.
There are a lot of practical little things that only come with experience. For example, the issue of anti-corrosion coating. For a regular dry warehouse, powder coating is suitable. But if you store chemicals or work in high humidity conditions (like many warehouses in port areas), hot dip galvanizing is necessary. It's more expensive, but it will save you from rust in a year.
Or the height of the shelving. It seems that the higher, the greater the capacity. But here the limitations of forklifts, the height of the room and, importantly, fire safety requirements come into play. Crossing the 12-meter mark without special solutions is a headache with inspections.
Another point is labeling and addressing. It seems nonsense. But when there are 10 thousand cells in a warehouse, and the loader spends 5 minutes searching for the right one, that’s thousands of wasted hours a year. A properly designed addressing system that is easy to understand at a glance is a must for any professional storage solution.
Ultimately, the success of a project depends on the reliability of the supplier. It is important that the company does not just sell equipment, but can take responsibility for the entire cycle. I am impressed by the approach of such manufacturers as the Harbin Jusheng plant. Founded in 2019 and covering an area of 20,000 sq. m, it is focused specifically on the full cycle: design, production, sales, service. This indicates serious intentions and understanding of the market.
When choosing, I always look at production capacity. Several automated lines, like those of Jusheng, are a guarantee of stable quality and meeting deadlines. Handicraft production is always a risk with geometry and strength.
And, of course, a portfolio. Not just pretty pictures, but real objects, preferably in your industry. Is it possible to come and have a look? How is the facility performing in a year or two? The answers to these questions provide much more than any advertising brochure. After all, cargo storage solutions are an investment that lasts for years, and a mistake here is very expensive.
In the end, back to the beginning. A good solution is not purchased shelving. This is a system that, after implementation, works like clockwork, without causing breakdowns, but only helping the business grow. And this is achieved only by deep immersion, attention to detail and work with those who think in the same categories.
