Running out of room in your warehouse? Before you start hunting for bigger premises, consider this: most warehouses are only about 60% efficient – with poor space utilisation a leading factor.
So, in many cases, the problem isn’t usually the size of your building – it’s how you’re using it.
Smart warehouse design can transform cramped, chaotic storage into organised, efficient operations that work magic for your business.
Whether you’re planning a complete warehouse fit-out or looking to optimise your existing space, here are some of our top must-have design features for effective storage:
Vertical Space: Your Untapped Goldmine
Most warehouses waste their greatest asset – height. While floor space is limited and expensive, vertical space costs nothing extra once you have the building.
Warehouse mezzanine floors represent one of the most effective ways to instantly double your usable space. Rather than expanding outwards, mezzanines let you build upwards, creating additional storage levels without the cost and disruption of moving premises.
These steel platforms can support heavy loads while providing safe access via stairs or goods lifts. The space underneath remains fully functional, effectively giving you two floors for the price of one. Many businesses find that mezzanine installations pay for themselves within months through improved efficiency.
Strategic Racking and Shelving Systems
Next up, racking and shelving. Not all racking for warehouse operations is created equal. The right system depends entirely on what you’re storing, how often you access it, and your operational workflow.
Selective pallet racking offers excellent accessibility – every pallet can be reached immediately without moving others. This works very well for businesses with diverse inventory or frequent stock rotation, though it requires more aisle space than alternatives.
Drive-in racking maximises density by eliminating aisles between storage bays. While you sacrifice some accessibility, you gain significant storage capacity, perfect for seasonal goods or slow-moving inventory.
For smaller items, cantilever racking systems handle awkward shapes and sizes that don’t fit standard pallets – timber, pipes, furniture, or any long, bulky items.
Warehouse Shelves: Small Changes, Big Impact
Warehouse shelves might seem basic compared to heavy-duty racking, but they often handle your most valuable and frequently accessed inventory. Poor shelving design creates bottlenecks that slow down your entire operation.
Consider these factors:
● Travel efficiency – Long runs of shelving create efficient storage but force pickers to travel greater distances
● Zone organisation – Breaking shelving into logical zones reduces travel time and makes inventory management more intuitive
● Height optimisation – Place frequently accessed items at waist level to reduce physical strain
● Safety access – Reserve higher shelves for slower-moving inventory with proper access equipment
Weighing up these factors, adjustable shelving systems offer maximum flexibility as your inventory mix changes, allowing you to optimise shelf spacing for current needs and adjust again when those needs evolve.
Floor Planning and Flow Design
Your floor plan determines how efficiently goods move through your warehouse. Poor layout design forces unnecessary travel, creates bottlenecks, and wastes time on every operation.
Essential considerations include:
● Clear pathways – Separate pedestrian traffic, forklift routes, and emergency access with clear marking
● Strategic positioning – Place high-turnover inventory closer to dispatch areas
● Seasonal planning – Position products for easy access during their peak demand periods
● Aisle width optimisation – Balance storage density with operational speed requirements
Of course, safety is paramount in floor design. Follow best practices for removing obstructions and preventing interruptions to movement between fire doors and exits.
Planning Your Warehouse Optimisation
At Spaceway, we’ve helped countless businesses across Hampshire and beyond solve their storage challenges. From warehouse mezzanine floors that doubled a packaging company’s capacity overnight, to complete warehouse fit-out projects that comprehensively transformed productivity.
We start with understanding your specific situation. What’s frustrating your team daily? Where are the bottlenecks? What would make the biggest difference to your operations?
Then we design solutions that truly fit how you work, not generic systems that look good on paper.
Whether you’re cramped for space, struggling with workflow, or planning for growth, we’ll work with you to create storage solutions that make sense for your business.
Ready to stop wrestling with your warehouse space? Contact us for a free survey. We’ll take a look at your operation and show you what’s possible – no obligation, just practical insights from people who understand storage.