Vertical Warehouse Storage: Principles for Using Space More Efficiently

To run an efficient warehouse, you need to maximize storage space — but often, that’s easier said than done. 

Per a common rule of thumb, about 22-27% of the total available floor space should be reserved for storage; as your business grows, keeping your total storage utilization within those numbers can be extremely difficult.

For modern warehouses, the obvious solution is vertical storage. Utilizing vertical space allows you to store more products, open up new routes for lift trucks, and enhance your team’s workflow. 

Here are a few general principles to keep in mind when implementing or optimizing vertical warehouse storage solutions.

Find Vertical Storage Systems That Fit Into Your Workflow

Vertical storage isn't just about adding height: Your goal is to seamlessly integrate these new systems in a way that improves throughput. To that end, you’ll need to choose the storage solutions that make the most sense for your facility. 

Consider how materials move through your facility, from receiving to shipping. Analyze the flow of goods and identify bottlenecks or inefficiencies. Then, select vertical storage solutions that complement and enhance these processes. 

For example, if you're dealing with palletized goods, forklifts may be sufficient for handling — but a Vertical Reciprocating Conveyor (VRC) may provide better utility if you’re moving large, individual items or bulky containers of parts.   

Review your workflow and ask questions:

• Are the stored items uniform in size?
• How frequently are the items accessed?
• Are any items sensitive to temperature, humidity, or light?
• How many access points are needed?
• How will inventory be tracked?

The key is to minimize travel time and maximize throughput. Often, that necessitates custom material handling equipment — but while customization requires an investment, it’s an investment that can quickly pay off when your storage strategy is aligned with your workflow. 

Related: The Semi-Automated Warehouse: A Task-Based Approach to Automation

Prioritize Safety, Ergonomics, and Training

Working at height increases the risk of falls and falling objects, which are two risk categories frequently cited in OSHA claims. 

Prioritize safety by investing in proper fall protection equipment, ensuring adequate lighting, and maintaining clear pathways. Ergonomics should be a key focus, too: Choose equipment and systems that minimize bending, lifting, and reaching. 

For example, if you’re manually handling materials that are stored vertically, flow racks (also known as Gravity Flow Racks) can feed products to the picker in an intuitive, efficient way.  

Employees must be trained on the safe operation of all equipment, including forklifts, order pickers, and any automated systems. Training should also cover proper lifting techniques, material handling procedures, and emergency protocols. 

Don’t Forget About Vertical Storage in the Battery Room

If you’re building vertically, you’re probably depending on forklifts to handle the heavy lifting. You need your lift trucks on the floor — and charged. In other words, the efficiency of your battery room will determine throughput of your warehouse.

Battery rooms can also benefit from vertical optimization. Battery racks can be stacked vertically to maximize storage density, then swapped out quickly with Operator Aboard Battery Extractors (BEs). 

BHS manufactures a variety of BEs with fully hydraulic operation, which allows for easier maintenance and longer operating lifespans. Each unit is engineered to minimize change-out times, and IIoT (Industrial Internet of Things) functionality allows managers to review session logs, system-health data, and other information to keep battery rooms running smoothly. 

Custom Solutions for Vertical Warehouse Storage

From ergonomic Gravity Flow Racks to Vertical Reciprocating Conveyors and custom battery rooms, BHS offers a range of solutions to help warehouses optimize space and efficiency. 

Our custom material handling solutions are engineered and manufactured entirely in our 148,000-square-foot, state-of-the-art facility in St. Louis, Missouri.  We utilize advanced manufacturing equipment such as laser cutters, CNC machines, and robotic welders to meet your operation’s unique needs — and help you achieve maximum throughput and ROI.

Review our custom manufacturing success stories and learn more about the process. If you’re ready to discuss custom solutions with a member of our team, call 1.800.247.9500 or request a quote online.