Modular Material Racks: How BHS Engineers a New Product

How does BHS design and build new products? The short answer: We take time to understand the need, then engage decades of engineering experience to find a solution. 

As our sales teams frequently tell end users, “if you can dream it, we can build it.” With that said, it’s helpful to see how that process actually works in the real world — particularly if you’ve wrestling with a material handling challenge that seems novel or unexpected.

A great example: The Modular Material Rack (SKU: 26301250) started as a custom solution for a high-volume client with a unique set of logistical constraints. By observing how this custom build solved a specific bottleneck, we were able to standardize the design, allowing the broader material handling industry to benefit from a field-tested solution.

Improving a Complex Cold-Storage Workflow

Several years ago, we received a request from an end user operating in cold storage. Their facility utilized double-deep (two-deep) racking and flow-through style rails.

Their process was highly specific:

• They needed to load three individual racks onto a pallet jack equipped with oversized forks.
• Workers would then travel to the racking, pick the necessary items, and scan a barcode located on the end of the rack to ensure inventory accuracy.
• Once loaded, these units were moved into freezer storage or dry goods areas before eventually being shipped to a last-mile facility for customer delivery.

The equipment needed to survive the mechanical stress of being transported three-at-a-row and the thermal shock of sub-zero environments. Aluminum racking wasn’t doing the job — and standard steel shelving didn’t provide enough flexibility to accommodate changing product lines.

The Solution: Modular Material Rack

We engineered a heavy-duty steel frame and modular shelving system that could withstand cold-storage temperatures. The Modular Material Rack is an easily modifiable shelving unit that’s capable of adapting on the fly.

Key features include:

• Storage Versatility: All four shelves can be adjusted in 2.5-inch (64-millimeter) increments. The entire unit can also knock down flat for storage when not in use.
• High Capacity: The Modular Material Rack features a total capacity of 2,000 lb (907 kg) with 200 lb (91 kg) per shelf.
• Durability: Designed for harsh environments, each unit is made with heavy-duty steel with a durable powder coat finish.
• Logistics Compatibility: Modular Material Racks can be placed on a mother cart to be tugged through a facility as part of a high-efficiency delivery train. They can also be transported with forklifts via four-way fork pockets.

The Modular Material Rack quickly became popular with our dealers and end users, who found a variety of ways to put it to work. One user told us that they were able to utilize the racks as a manual backup whenever their primary conveyor systems experienced downtime — saving thousands of dollars in lost throughput.

The BHS Custom Engineering Process

We proudly design and manufacture all of our equipment in the USA at our 148,000-square-foot facility in St. Louis, Missouri. By centralizing our approach, we're able to move quickly from a custom prototype to a standardized product.

Our sales and engineering teams collaborate in the same building where our fabrication experts operate laser cutters, CNC machines, and robotic welders. When a client presents a challenge that off-the-shelf equipment can't solve, we get to work:

• Application Assessment: We analyze the environment, including floor conditions, temperature, and weight capacities.
• 3D Digital Modeling: We provide detailed approval drawings and 3D models so the end user can verify the equipment fits their existing floor plan.
• Precision Fabrication: We build the solution to exacting tolerances, ensuring it integrates with other warehouse technology.
• Real-World Use and Modifications: Where needed, we’re able to quickly refine features based on operator feedback.

By working closely with dealers and end users, we create tailored solutions that begin providing value on day one. Whether you need a standard storage solution or a completely custom build, our team in St. Louis is ready to engineer equipment that fits your specific bottleneck.

To learn more about our standardized material handling solutions, contact our sales team at 1.800.BHS.9500.