Redesigning the layout of an existing racking or shelving system can significantly improve the amount of storage space available and the operational efficiency of warehouses, says storage and materials handling equipment manufacturer Linvar marketing manager Nicky Farrell.

She highlights that careful consideration of warehouse design can have significant cost-saving implications, adding that this is especially relevant to Linvar’s clients in the mining industry, whose business activities have slowed, owing to the fall in commodity prices.

“In general, mining companies have tightened their belts on any capital expenditure. However, our range of products, including containers, linbins, bulk storage, shelving and racking, as well as factory and warehouse equipment, together with our design, manufacturing and installation capabilities, enable us to help companies manage their costs through effective product storage and handling systems.

“The goal of a warehouse’s layout is to improve warehousing functions and achieve maximum efficiency and use of space,” she says, pointing out that, while the objectives of warehouse layout and operation are recognised by most businesses, layout can be complicated when a variety of products with different space requirements need to be stored, and there are drastic fluctuations in product demand.

To help businesses manage these problems and increase the efficient use of storage space, Linvar offers feasibility studies to advise warehouse managers on achieving the most effective design for particular products and operational needs.

Farrell explains that a warehouse is typically divided into areas to support everyday processes, such as reserve storage, forward pick, cross docking, shipping, receiving, assembly and special handling lines, and quality inspection. Designing a new facility requires the analysis of current and projected data on the activities in each of these areas, with special focus on receiving, shipping and inventory levels. Further, this data should be supported by a consideration of factors, such as process flows, materials handling equipment, type and style of racking equipment, special handling requirements and personnel.

When planning the layout and operation of any warehouse system, Farrell says, there are fundamental principles that should be followed to ensure a general good practice. The most suitable unit load should always be employed to avoid overloading; space should always be used in the most efficient way possible; the movement of inventory should be controlled and reduced as far as possible to prevent loss and breakage; operating costs should be limited; and the environment should be made safe, secure and environment friendly.

“Successful warehouse layout must adhere to these principles regardless of the materials being stored to make the most of the space, equipment and labour available; it must also ensure the protection of items and improve the accessibility of items.”

Farrell highlights that differing trends in storage designs are emerging in different areas, pointing out that, in Johannesburg, for example, more clients are looking to expand their storage areas upwards instead of outwards, owing to the high price of land. This has led to increased interest in the use of existing mezzanine floors, instead of expanding floor space, to decrease costs.

Linvar has branches throughout Africa and has noted growing demand for its products and services in Zambia, the Democratic Republic of Congo, Ghana, Tanzania, Namibia, Angola and Mozambique.