Hybrid Racking Project for FMCG – Vinatech Australia

Problem

FMCG and consumer goods warehouses often handle different inventory profiles within the same facility. Fast-moving products and high-SKU inventory require quick, direct pallet access, while bulk products with larger quantities can benefit from higher-density storage.

For this 5,000 m² warehouse, using only one type of racking system would limit operational efficiency. A fully Selective layout would provide excellent accessibility but use more floor space for forklift aisles, while a fully Drive-In configuration would increase storage density but reduce direct access to individual pallets.

The customer therefore required a solution that could:

• Increase pallet capacity within the existing 5,000 m² footprint
• Maintain direct access for fast-moving and high-SKU products
• Provide higher-density storage for bulk inventory
• Improve zoning between different product and inventory profiles
• Reduce unnecessary aisle space
• Support seasonal fluctuations in FMCG inventory

The key challenge was to achieve the right balance between pallet accessibility, storage density and operational flexibility.

Solution

Vinatech developed a hybrid storage configuration combining Selective Pallet Racking and Drive-In Racking, with each system assigned according to product movement, SKU profile and inventory volume.

Selective Pallet Racking was used for fast-moving goods and products requiring frequent individual pallet access. These zones provide approximately 2,700 pallet positions, allowing operators to quickly locate and retrieve different SKUs.

Drive-In Racking was introduced for high-volume products with fewer SKUs. By storing pallets several positions deep and reducing the number of forklift aisles required, these zones provide approximately 2,100 pallet positions while achieving up to 50% higher storage density than a comparable Selective configuration within the allocated area.

Together, the two systems provide approximately 4,800 pallet positions across the 5,000 m² warehouse, equivalent to around 960 pallet positions per 1,000 m² of total warehouse floor area.

The integrated configuration includes:

• Approx. 2,700 Selective pallet positions
• Approx. 2,100 Drive-In pallet positions
• Approx. 4,800 total pallet positions
• Approx. 960 pallet positions per 1,000 m²
• Direct pallet access for fast-moving and high-SKU inventory
• High-density deep-lane storage for bulk products
• Dedicated storage zones based on inventory characteristics

Rather than applying the same storage method throughout the warehouse, the hybrid design matches each racking system to the inventory it handles.

Outcome

The integrated Selective and Drive-In configuration enables the customer to increase storage capacity while preserving accessibility for products that require frequent handling.

Compared with a conventional all-Selective configuration, the hybrid layout provides approximately 25% more pallet capacity within the same 5,000 m² warehouse footprint. The higher-density Drive-In zones allow more bulk inventory to be consolidated into a smaller area, freeing additional warehouse space for fast-moving products and operational activities.

The project delivered:

• Approx. 25% increase in overall pallet storage capacity
• Up to 50% higher storage density within designated Drive-In zones
• More efficient separation of fast-moving and bulk inventory
• Reduced aisle requirements for high-volume product storage
• Improved inventory organisation across different SKU profiles
• Better utilisation of the existing warehouse footprint
• Greater flexibility during seasonal inventory peaks

For the customer, the hybrid approach provides a more practical balance between high-density storage and direct pallet accessibility, allowing the warehouse to accommodate more inventory without compromising the efficiency of day-to-day FMCG operations.

Testimonial

“The combination of Selective and Drive-In Racking gives us greater flexibility in how we manage different types of inventory. Fast-moving products remain easy to access, while bulk stock can be stored more efficiently in the high-density zones. The new layout has increased our overall storage capacity and helped us make better use of the available warehouse space.”

– Warehouse Operations Manager, FMCG & Consumer Goods Distribution

Vinatech Australia – Pallet Racking & Industrial warehouse racking solutions

• Website: https://vinatech.com.au/
• Phone number: 0485 083 868
• Email: info@vinatech.com.au
• Address: 34 Paramount Bvd, Cranbourne West VIC 3977, Australia