Multi-Tier Racking System with 4,680 Pallet Positions for Large E-Commerce Fulfillment Center
Summary
Craftsman Storage maximized storage density for a leading Indian e-commerce fulfillment center with a Multi-Tier Racking System spanning 87m x 43m x 13m height, delivering 4,680 pallet positions, multi-SKU support, and high operational uptime without expanding the floor footprint.
Problem Statement & Challenges Faced
The fulfillment center needed a smarter way to:
- Store multiple SKU types of varying sizes
- Improve picking speed for fast-moving e-commerce orders
- Expand storage without relocating or increasing footprint
- Utilize available vertical height effectively
- Maintain high operational uptime & inventory accessibility
Traditional racking was no longer sustainable for space or performance targets.
Products Offered
- Overall Storage Area
- Length: 87 m
- Width: 43 m
- Height: 13 m
- Storage Capacity
- 4,680 pallet positions
- SKU Support
- Length: Multiple SKUs- ideal for e-commerce order mix
A Multi-Purpose Racking Storage System was proposed and installed with the following specifications:
This solution leveraged the facility’s height to create multi-level operational space.
The Solution
- High-density vertical racking to maximize cubic space
- Multiple operational levels enabling simultaneous picking
- Zonal stock segregation for SKU accessibility and faster order turnaround
- Efficient aisle layouts supporting smooth material movement
- Strong structural design ensuring safety and load integrity
To meet throughput and space optimization goals, the multi-tier storage system was developed with:
This configuration transformed floor space into usable storage volume across tiers.
The Benefits
| Benefit | Outcome |
|---|---|
| Increased Storage Density | 4,680 pallets stored within the same footprint |
| Better Space Utilization | Full 13-meter height efficiently used |
| Faster Order Picking | Multi-level access improved picking speed |
| SKU Flexibility | Supports large variety of products |
| Lower Expansion Costs | No need for additional facility area |
| Higher Productivity | Reduced congestion and streamlined workflow |
The warehouse now operates with greater capacity, flexibility, and fulfillment efficiency.
The Summary
The Multi-Tier Racking System enabled the warehouse to:
- Scale storage capacity significantly
- Improve operational flow and turnaround time
- Maintain delivery performance during peak demand
- Future-proof the facility for continued growth
Smarter storage today - stronger fulfillment tomorrow.
