FMCG Distribution Racking Project – Vinatech Australia

Project: FIFO Storage Upgrade for High-Volume Distribution
Total Area: Approx. 7,500 m²
Industry: FMCG, Food & Beverage, Cold Storage & Retail Distribution
System: Pallet Flow Racking

Problem

For high-volume distribution operations, warehouse efficiency depends on keeping inventory moving while maintaining reliable stock rotation. Products need to move from receiving to dispatch without unnecessary handling or delays.

At this approximately 7,500 m² facility, the project focused on increasing storage capacity and improving access to stock in the correct sequence. The storage solution needed to accommodate multiple pallets per SKU while supporting frequent replenishment and retrieval.

The key requirements included:

• Increasing pallet capacity within the existing warehouse footprint
• Supporting First In, First Out (FIFO) stock rotation
• Organising fast-moving inventory into dedicated storage lanes
• Reducing unnecessary pallet repositioning
• Separating replenishment and retrieval activities
• Maintaining a consistent supply of pallets at the picking face

The challenge was to combine high-density storage with a controlled flow of goods, helping operators retrieve older stock without moving newer pallets out of the way.

Solution

Vinatech Australia’s Pallet Flow Racking solution combines deep-lane storage with gravity-fed pallet movement, supporting FIFO handling from separate loading and retrieval aisles.

The proposed configuration provides approximately 5,400 pallet positions across four storage levels, with each lane accommodating six pallets in depth. This arrangement makes use of warehouse height and storage depth while maintaining access at both ends of the system.

Pallets are loaded at the higher end of an inclined roller lane and move towards the retrieval face under gravity. As the front pallet is removed, the remaining pallets advance towards the unloading position. Suitable speed-control and pallet-separation components help regulate movement and support controlled retrieval.

With loading and unloading taking place at opposite ends, the first pallet entering a lane is the first available for retrieval. Each lane is assigned to a compatible SKU and stock sequence, helping maintain consistent rotation.

For products managed by expiry date, this physical FIFO flow should be supported by appropriate batch allocation and inventory controls to meet First Expired, First Out (FEFO) requirements.

The proposed configuration incorporates:

• Approx. 5,400 pallet positions
• Four storage levels
• Storage lanes six pallets deep
• Gravity-fed roller lanes with controlled pallet movement
• Separate loading and retrieval aisles
• Dedicated lanes for individual SKUs and stock sequences
• Pallet compatibility checks to support reliable operation

The system is designed to keep replenishment and retrieval moving independently while bringing the next available pallet towards the picking face.

Outcome

The proposed warehouse configuration is designed to provide a denser storage layout and more consistent stock rotation within the existing 7,500 m² facility.

With an indicative capacity of 5,400 pallet positions, the project targets an approximately 35% increase in storage capacity compared with an assumed previous layout of 4,000 positions. This would provide additional inventory capacity without expanding the building.

Gravity-fed movement brings pallets towards the retrieval face, reducing the need for forklifts to travel into storage lanes. Combined with separate replenishment and retrieval aisles, the configuration targets an approximately 20% reduction in average pallet retrieval time, subject to verification under comparable operating conditions.

The anticipated operational benefits include:

• Approximately 35% more pallet storage capacity against the assumed baseline
• A target 20% reduction in average pallet retrieval time
• More consistent FIFO stock rotation within each lane
• Reduced pallet repositioning to access older inventory
• Less interference between loading and retrieval activities
• Clearer organisation of SKUs and stock batches
• A steady supply of pallets at the retrieval face during busy periods

For fast-moving distribution operations, the solution provides a structured flow from replenishment to retrieval, supporting both storage efficiency and daily dispatch requirements. Final capacity and performance improvements will depend on the approved layout, pallet quality, product mix and operating practices.

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