Case Study: Not Enough Warehouse Racks? Double Storage Capacity Without New Racking

As businesses continue to grow, many companies choose to move to larger warehouses to accommodate increasing inventory. However, having a larger warehouse does not necessarily mean having more storage capacity. If the number of storage racks is insufficient, the warehouse space may not be used efficiently.

This was the case for an electrical appliance distributor in Bang Sao Thong District, Samut Prakan, which moved to a larger warehouse and brought its existing storage racks from the previous facility for continued use. Although the new warehouse had more available space, the existing racks were not sufficient for the increased volume of inventory. As a result, some products still had to be stored on the floor.

In this case study, UPR Thailand explores why the company still faced storage capacity issues despite moving to a larger warehouse and how it addressed the problem with the use of Inverted Nesting Racks (U-Rack Inverted) — without the need to invest in permanent racking systems.

Case Overview — Customer Profile

• Business Type: Electrical appliance distributor
• Location: Bang Sao Thong, Samut Prakan
• Warehouse Type: Rented warehouse
• Usable Area: Approximately 42 × 50 meters, using only around one-third to one-quarter of the total warehouse area

Pain Point — A Larger Warehouse, but Still Not Enough Storage Space

After moving to the new warehouse in hopes of more storage capacity, the company immediately continued using its existing Nesting Racks because they were still in good condition and suitable for continued operation. However, several challenges remained:

• Insufficient storage capacity: Even after installing the existing Nesting Racks, some products still had no available rack space and had to be stored on the floor.
• Underutilized vertical space: The warehouse still had available space, but it could not be effectively utilized to increase storage capacity.
• Reduced operational efficiency: Products stored on the floor were more difficult for forklifts to access and move, resulting in longer picking and storage times.
• Higher risk of product damage: Products stored directly on the floor for extended periods could be more vulnerable to damage or handling errors.

In addition, the customer had another important limitation: they did not want to install Selective Racking because the warehouse was rented. If they needed to move to another warehouse in the future, they would have to bear the additional costs and time required to dismantle and reinstall the racking system.

Therefore, the challenge was not simply to increase storage capacity. The solution also needed to improve operational efficiency, maintain ease of relocation, and avoid permanently altering the warehouse structure.

Solution — Flexible Storage Expansion with Inverted Nesting Racks

After conducting an on-site assessment and analyzing the customer’s storage requirements, UPR Thailand recommended 230 Inverted Nesting Racks (U-Rack Inverted) to accommodate the increased inventory volume, while continuing to use the customer’s existing Nesting Racks.

This solution addressed both the limitations of a rented warehouse and the need for additional storage capacity. The racks were ready to be put into operation immediately, relocated when the warehouse was moved, and used to maximize vertical storage space without disrupting day-to-day warehouse operations.

What Is an Inverted Nesting Rack (U-Rack Inverted)?

An Inverted Nesting Rack (U-Rack Inverted) is a type of warehouse rack designed to increase storage capacity without requiring permanent installation. It is particularly suitable for rented warehouses, businesses that frequently modify their warehouse layouts, and companies looking for a cost-effective and flexible way to increase storage capacity.

Key Benefits of Inverted Nesting Racks

• No floor anchoring or permanent installation required: The racks can be positioned and used immediately without being fixed to the floor or building structure.
• Easy to relocate and reposition: They can be moved when warehouse layouts change or transferred to a new warehouse.
• Maximize vertical storage space: Make better use of available warehouse space without construction or permanent racking installation.
• Forklift compatible: Designed to support convenient product storage and retrieval using forklifts.
• Improve warehouse organization: Reduce floor storage and make better use of available warehouse space.

Inverted Nesting Racks are therefore an effective option for businesses looking to increase storage capacity while maintaining flexibility in warehouse management and long-term investment.

Result — Storage Capacity Doubled Without Permanent Racking

After implementing the Inverted Nesting Rack (U-Rack Inverted) solution, the customer significantly increased storage capacity—from 115 pallets to 230 pallets.

Previously, some products had to be stored directly on the floor. With the new solution, the customer could utilize stacked storage by adding one additional level of Inverted Nesting Racks. In this case, the customer used the Inverted Nesting Racks to create an additional storage level, allowing the available warehouse space to be utilized more efficiently.

Key Results

• Doubled the storage capacity, from 115 to 230 pallets
• Improved utilization of vertical warehouse space
• Reduced floor storage, resulting in a more organized warehouse
• Improved forklift accessibility, making product handling more convenient and efficient
• Avoided the cost of installing Selective Racking, which was not suitable for the rented warehouse
• Retained the flexibility to relocate the Nesting Racks to a new warehouse if the business changes its operating location in the future

Our solution enabled the customer to improve warehouse space utilization quickly without making structural modifications to the facility or interrupting warehouse operations, while also maintaining mobility for future relocations.

UPR Thailand received direct feedback from the customer’s warehouse team:

“It has made a big difference. The Nesting Racks are high quality and easy to use. Our operations are much more convenient, and using forklifts to pick up the products is much easier.”

— Warehouse Staff

Frequently Asked Questions (FAQ)

Q: Are Nesting Racks suitable for rented warehouses?

A: Yes. Nesting Racks are particularly suitable for rented warehouses because they do not require permanent installation or floor anchoring. They can be repositioned or relocated to a new warehouse, helping reduce costs when a business changes its operating location.

Q: How much additional storage capacity can Inverted Nesting Racks provide?

A: The additional capacity depends on the warehouse layout and the type of products being stored. Inverted Nesting Racks can increase vertical storage by up to 2 additional levels. From a single pallet stored directly on the floor, up to two Nesting Racks can be stacked, allowing pallets to be stored across a total of up to 3 levels.

Q: Does the warehouse need to stop operations for installation?

A: No. Nesting Racks do not require permanent installation. They simply need to be positioned in the desired location and can be used immediately. This helps minimize disruption to ongoing warehouse operations.

Q: What types of businesses are Nesting Racks suitable for?

A: Nesting Racks are ideal for distribution centers, factories, logistics businesses, and companies with fluctuating inventory. They are especially suitable for rented warehouses, as they can be easily moved, nested when not in use, and adjusted to meet changing storage needs.

When Storage Space Is Limited, UPR Thailand Is Ready to Help

If your business is facing limited storage capacity, products stored directly on the floor, underutilized vertical space, or does not want to invest in permanent racking systems, choosing the right warehouse racking and storage solution can help maximize storage capacity while providing greater flexibility for long-term operations.

The experts at UPR Thailand are ready to conduct an on-site assessment, analyze your storage requirements, and recommend a solution that fits your operational needs. Our goal is to help businesses maximize warehouse space, improve storage efficiency, and prepare for future growth.

UPR (Thailand) Co., Ltd.

TEL: +66-2-672-5100

EMAIL: info-thailand@upr-net.co.jp