Consumer Goods Selective Racking Project – Vinatech Australia

Problem

FMCG and consumer goods distribution centres operate in a demanding warehouse environment. Large numbers of SKUs, high inventory turnover and frequent inbound and outbound movements mean that storage capacity alone is not enough. Pallets must also be quickly accessible to keep goods moving efficiently through the warehouse.

For this 20,000 m² facility with a height of 15 metres, one of the key challenges was making better use of the available vertical space. Without an optimised racking system, a significant proportion of the warehouse volume could remain underutilised, while floor-level storage would require more space and make inventory organisation increasingly difficult as volumes increased.

The FMCG operation also required rapid access to individual pallets. Different product categories, SKUs and inventory batches may need to be retrieved throughout the day, making deep-storage configurations less suitable where direct pallet accessibility is a priority.

Solution

Vinatech designed a Selective Pallet Racking System specifically around the operational requirements of the distribution centre.

The system uses the warehouse’s 15 m height to create multiple vertical storage levels, significantly increasing pallet capacity without expanding the building footprint. Instead of relying heavily on floor-level storage, inventory is organised vertically into clearly defined pallet locations.

Selective Pallet Racking was chosen because it provides 100% direct access to every pallet position. Forklift operators can therefore retrieve the required pallet directly from the aisle without relocating other stock first – an important advantage for an FMCG warehouse handling many SKUs and frequent order cycles.

The warehouse layout was also planned around material flow. Clearly defined forklift aisles and storage zones help separate storage, retrieval and replenishment activities while maintaining efficient access throughout the facility.

Outcome

The new Selective Pallet Racking System transformed the warehouse from a predominantly floor-space-driven operation into a structured vertical storage environment.

With approximately 16,800 pallet positions, the completed system increased available pallet storage capacity by approximately 65% compared with the previous storage configuration. The warehouse can therefore accommodate substantially more inventory without requiring additional floor area or facility expansion.

Operational efficiency also improved. With every pallet directly accessible, forklift operators spend less time repositioning stock or waiting for access to blocked pallet locations. The optimised layout contributed to an estimated 25% reduction in average pallet retrieval time.

Combined with improved aisle organisation and direct pallet access, the warehouse is capable of handling approximately 30% more pallet movements during operating periods, providing greater throughput for receiving, replenishment and dispatch activities.

The project delivered:

• ~16,800 pallet positions within 20,000 m²
• ~65% increase in pallet storage capacity
• ~30% increase in pallet handling throughput
• ~25% reduction in average pallet retrieval time
• Greater flexibility for high-SKU FMCG inventory
• Improved forklift circulation and material flow
• Additional capacity to manage seasonal inventory peaks without expanding the warehouse footprint

For the customer, the result is a warehouse that can store more inventory, move pallets faster and respond more effectively to fluctuations in FMCG demand.

Testimonial

“The new racking system has made a significant difference to both our storage capacity and daily warehouse operations. We can now store more than 16,000 pallets within the facility while keeping every pallet directly accessible. The improved layout also allows our team to move stock faster during busy receiving and dispatch periods, which is particularly important in FMCG distribution.”

— Operations Manager, FMCG & Consumer Goods Distribution Centre

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