FMCG VNA Racking Project – Vinatech Australia

• Project: Narrow Aisle Warehouse Upgrade for High-Density Storage
• Total Area: Approx. 10,000 m²
• Industry: FMCG Warehouses
• System: VNA Racking

Problem

For FMCG warehouses managing a wide range of product lines, increasing storage capacity needs to go hand in hand with maintaining direct access to inventory. Operators must retrieve individual pallets efficiently as replenishment priorities and dispatch requirements change throughout the day.

At this approximately 10,000 m² facility, the project focused on accommodating more palletised goods within the existing building. The storage approach needed to make better use of available warehouse height and reduce the floor area dedicated to working aisles.

The key requirements included:

• Increasing pallet capacity without expanding the warehouse
• Making better use of available vertical storage space
• Maintaining direct access to every pallet position
• Accommodating a broad mix of FMCG products and SKUs
• Supporting stock selection by batch and expiry date
• Matching aisle dimensions and rack heights to suitable handling equipment

The challenge was to achieve higher storage density while preserving the individual pallet access needed for a varied, fast-moving inventory.

Solution

Vinatech Australia’s Very Narrow Aisle (VNA) Racking solution combines closely spaced rack rows with multi-level storage, allowing more of the warehouse footprint and height to be used for inventory.

The proposed configuration provides approximately 12,000 pallet positions across six storage levels. Final rack heights and aisle widths would be coordinated with pallet dimensions, load requirements, building clearances and the selected VNA handling equipment.

Unlike deep-lane storage, VNA Racking retains direct access to each pallet position. This allows operators to select the required SKU or batch without first moving pallets stored in front of it—a useful feature for FMCG operations managing different turnover rates and replenishment schedules.

The system requires compatible VNA trucks, with aisle guidance where specified by the equipment supplier. Floor condition, operating clearances and aisle-end transfer areas are also essential parts of the layout design.

The proposed configuration incorporates:

• Approx. 12,000 pallet positions
• Six storage levels
• Very narrow working aisles matched to the selected handling equipment
• Direct access to every pallet position
• Dedicated locations for individual SKUs and batches
• Planned transfer areas at the ends of rack aisles
• Rack and equipment coordination for high-level pallet handling

Direct pallet access also supports FIFO or FEFO stock selection when paired with accurate batch records and appropriate inventory procedures. The racking provides accessibility; warehouse controls determine the retrieval sequence.

Outcome

The proposed VNA layout is designed to increase pallet capacity within the existing 10,000 m² facility while retaining the flexibility to retrieve individual product lines.

With an indicative capacity of 12,000 pallet positions, the project targets approximately 40% more storage capacity than an assumed baseline of around 8,570 positions. This would create additional room for inventory by reducing aisle space and making better use of available storage height.

For daily operations, individual pallet accessibility supports a broad SKU mix and allows stock to be selected according to order priorities, batch requirements or expiry dates. Dedicated locations also provide a clearer structure for inventory tracking and replenishment.

The anticipated operational benefits include:

• Approximately 40% more pallet capacity against the assumed baseline
• Direct access to every pallet position
• Better use of warehouse height and floor space
• Greater flexibility to manage products with different turnover rates
• Reduced need to reposition surrounding pallets to access a specific load
• Clearer organisation of SKUs, batches and pallet locations
• Additional capacity for seasonal and promotional inventory

For the FMCG operation, the solution provides a denser storage layout while preserving access to individual pallets. Final capacity and handling performance will depend on the approved design, truck specification, floor conditions and inventory profile.

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