Nanjing Peter Logistics Equipment Co., Ltd.

Project Overview A building materials supplier in Iraq was struggling with the storage and handling of long, heavy materials—primarily wooden boards and steel plates—that were occupying excessive floor space and creating safety hazards. The client needed a dedicated racking solution to organize these oversized materials, improve accessibility, and maximize their warehouse footprint. Our team delivered a custom cantilever racking system designed specifically for the demands of Iraq's construction material supply chain. The Challenge Before the cantilever racking installation, the client's warehouse faced multiple operational difficulties: Floor-level chaos: Wooden boards and steel plates were stacked directly on the floor in unorganized piles, occupying over 60% of the available floor area Material damage: Direct ground contact caused moisture absorption in wooden boards and surface corrosion on steel plates, resulting in an estimated 8% material loss per quarter Safety risks: Unstable stacks of heavy steel plates posed serious workplace hazards, with two near-miss incidents reported in the previous year Inefficient retrieval: Workers spent an average of 22 minutes locating and extracting specific material dimensions from mixed floor stacks Inventory blind spots: Without organized racking, accurate stock counting was nearly impossible, leading to frequent over-ordering or stockouts The Solution: Custom Cantilever Racking System After analyzing the client's material dimensions, weight profiles, and daily throughput, we designed and installed a heavy-duty cantilever racking system with the following configuration: Dual-Sided Cantilever Configuration A double-sided cantilever racking row was installed as the central spine of the storage area. One side was dedicated to wooden boards with wider arm spacing to accommodate varying board lengths (2.4m to 6m), while the opposite side was configured for steel plates with reinforced arms rated at 1,200 kg per level to handle the heavy load. Heavy-Duty Arm Design Each cantilever arm was fabricated from structural steel with a hot-dip galvanized finish to withstand Iraq's extreme temperature fluctuations (ranging from 5°C in winter to over 50°C in summer). The arms were bolted to vertical columns at adjustable intervals, allowing the client to reconfigure storage levels as their inventory mix evolved. Clear Aisle Access The open-front cantilever design eliminated the need for vertical front columns, enabling forklift operators to load and retrieve materials from either side without obstruction. Dedicated 3.5-meter-wide aisles ensured safe maneuvering even with 6-meter-long timber loads. Key Results MetricBeforeAfterImprovement Floor Space Freed60% occupied22% occupied38% reclaimed Material Retrieval Time22 min6 min-73% Material Loss Rate8% per quarter1.5% per quarter-81% Storage Capacity~80 tonnes~210 tonnes+163% Inventory AccuracyEstimate only95%Fully trackable Operational Impact Material preservation: Elevated storage off the ground eliminated moisture damage to wooden boards and surface rust on steel plates, preserving material quality for end customers Workplace safety: Organized, stable racking with clear load ratings and aisle markings eliminated stacking-related hazards completely Faster order fulfillment: Categorized storage by material type, thickness, and length enabled pickers to locate items in under 6 minutes—a 73% time reduction Real-time inventory visibility: With materials organized on dedicated cantilever arms, stock-taking became fast and accurate, enabling better procurement planning Scalable design: The modular cantilever system can be extended with additional bays as the client's business expands across Iraq's growing construction market Client Feedback “We used to dread receiving new steel plate shipments because we had nowhere proper to put them. Now, everything has its place. Our warehouse looks completely different—organized, professional, and most importantly, safe. The cantilever system handles the weight perfectly. We are already planning to add more bays next year." Conclusion This Iraq-based project highlights the transformative impact of a purpose-built cantilever racking system for building materials storage. By replacing chaotic floor stacking with a structured, heavy-duty racking solution, the client reclaimed 38% of warehouse floor space, increased total storage capacity by over 160%, and virtually eliminated material loss. For any business handling long, heavy materials such as timber, steel plates, pipes, or profiles, a cantilever racking system represents one of the highest-ROI warehouse investments available.

Project Overview In the rapidly evolving logistics landscape of the Caribbean, a Barbados-based warehousing and distribution company faced a critical challenge: their existing storage infrastructure was failing to keep pace with growing inventory demands. Limited floor space, inefficient product organization, and workflow bottlenecks were impacting daily operations and bottom-line performance. The client needed a comprehensive storage solution that would not only increase usable square footage but also streamline material handling processes across their facility. The Challenge Prior to the upgrade, the Barbados warehouse relied on a mix of ad-hoc shelving units and floor-level stacking, resulting in: Low storage density: Only 40% of vertical space was being utilized Inefficient picking paths: Staff spent 35% of shift time navigating disorganized aisles Inventory damage risk: Improperly stacked goods led to recurring product loss Limited scalability: Seasonal inventory surges overwhelmed available capacity The Solution: Multi-Racking System Deployment After a thorough on-site assessment, our engineering team designed and deployed a three-tier racking ecosystem tailored to the client's diverse inventory profile: 1. Cantilever Racking — Long & Bulky Items Cantilever racking was installed along the warehouse perimeter to accommodate long, irregularly shaped materials including steel pipes, timber beams, and extruded profiles. The open-front design enabled forklift operators to load and retrieve items without obstruction, reducing handling time by 28% compared to the previous floor-stacking method. 2. Pallet Racking — High-Volume Bulk Storage A selective pallet racking system was configured as the backbone of the warehouse, providing four-tier vertical storage for palletized goods. This system alone increased SKU capacity by 60% while maintaining FIFO (First-In-First-Out) inventory rotation. Adjustable beam levels allowed the client to reconfigure shelf heights as product dimensions changed seasonally. 3. Shelf Racking — Small Parts & Picking Efficiency Medium-duty shelf racking was deployed in the picking zone for smaller, fast-moving items. Integrated with labeled bin locations and barcode scanning, this zone reduced picking errors by 40% and cut order fulfillment time from 45 minutes to 18 minutes per order cycle. Key Results Metric Before After Improvement Usable Storage Area 1,200 m² 2,050 m² +71% Vertical Space Utilization 40% 85% +112% Order Picking Speed 45 min/cycle 18 min/cycle -60% Inventory Accuracy 82% 97% +15% Picking Errors 12 per day 3 per day -75% Operational Impact Beyond the quantitative gains, the new racking infrastructure delivered significant qualitative improvements: Safety compliance: Dedicated racking aisles and clear load-rating signage aligned the facility with OSHA and regional safety standards Staff satisfaction: Organized and accessible inventory reduced physical strain and improved workplace morale Client confidence: Faster, more accurate order fulfillment strengthened the company's reputation with Barbados-based retailers and regional distribution partners Future-ready: The modular racking design supports bolt-on expansion as the business continues to grow Client Feedback “The transformation was beyond our expectations. We went from operating in a cramped, chaotic space to a modern, efficient warehouse. The cantilever racks alone freed up an entire bay of floor space we didn't know we had. Our pickers are happier and our customers are noticing the difference in delivery speed.” Conclusion This Barbados warehouse project demonstrates how a strategically designed multi-racking solution—combining cantilever, pallet, and shelf racking—can unlock hidden capacity within existing footprints. By increasing usable storage area by over 70%, reducing picking time by 60%, and eliminating nearly all picking errors, the client achieved a full return on investment within 14 months. Whether your facility handles long-span materials, high-volume pallets, or high-SKU small parts, a customized racking configuration can deliver measurable ROI while future-proofing your operations for growth.

Project Overview An established construction company based in Australia sought to optimize their warehouse storage capacity to accommodate growing inventory demands. After evaluating multiple storage solutions, they selected our heavy-duty pallet racking system for its superior load-bearing capacity, modular design, and ease of installation. Client Background The client operates in the competitive Australian construction sector, managing a wide range of building materials and equipment. With expanding operations, their existing warehouse layout could no longer support efficient inventory management, leading to congestion, safety concerns, and reduced operational productivity. The client required a scalable, durable storage solution that could handle heavy construction materials while maximizing the use of vertical space within their existing facility. Solution Delivered We provided a comprehensive pallet racking solution consisting of 500 units of heavy-duty racking, each measuring 2700mm (W) × 1000mm (D) × 6000mm (H). The system was configured as a 4-level structure, with each level engineered to support a 2-ton load capacity per shelf level, delivering a total storage capacity of 4,000 tons across the entire installation. Key Specifications Parameter Specification Total Units 500 sets Dimensions (W×D×H) 2700 × 1000 × 6000 mm Configuration 4 levels per unit Load Capacity 2 tons per level (8 tons per unit) Total System Capacity 4,000 tons Application Construction material & equipment storage Location Australia Installation & Deployment The entire 500-unit system was shipped and installed on schedule. Our pallet racking features a modular bolt-together design that enabled the client's on-site team to complete assembly efficiently with minimal downtime. The client specifically highlighted the straightforward installation process, which required no specialized tools or extensive training — a critical advantage for a busy construction warehouse environment where time is at a premium. Heavy-Duty Pallet Racking System — On-Site Deployment 4-Level Pallet Racking — Warehouse Storage Optimization Results & Client Feedback The project delivered measurable improvements across multiple operational dimensions: Space Utilization: The 4-level vertical configuration dramatically increased storage density within the same warehouse footprint, effectively multiplying the usable storage area and eliminating the need for costly facility expansion. Operational Efficiency: Streamlined aisle access and organized tiered storage significantly reduced picking and replenishment times, enabling faster turnaround on construction material dispatch. Load Safety: The 2-ton per level capacity comfortably accommodates heavy construction materials, with robust structural integrity ensuring long-term reliability and workplace safety compliance. The client reported being highly satisfied with both product quality and the installation experience: "The racking is of excellent quality and remarkably easy to install. The system has significantly improved our warehouse space utilization and operational workflow. We are very pleased with the outcome." Why This Solution Stands Out This deployment demonstrates the practical advantages of our heavy-duty pallet racking for the construction industry: Scalable Design: The modular structure allows future expansion or reconfiguration as storage needs evolve, protecting the client's investment. Heavy-Duty Performance: Engineered for demanding industrial environments with consistent 2-ton per level load ratings across all 500 units. Rapid Installation: Bolt-together assembly minimizes downtime and accelerates time-to-value — a key factor for the client's operational continuity. Durable Construction: High-grade steel components with protective finishes ensure longevity even under continuous heavy use in harsh warehouse conditions. Conclusion This project underscores our commitment to delivering industrial-grade storage solutions that drive tangible operational gains. The Australian construction client now operates with a significantly more organized, safer, and higher-capacity warehouse — a direct and measurable outcome of the 500-unit pallet racking deployment. We continue to support the client as their storage needs evolve, reinforcing a long-term partnership built on product quality and service reliability.

Australian Timber Storage Cantilever Racking Project Case This professional heavy-duty cantilever racking solution was fully delivered for a large timber supply enterprise based in Queensland, Australia, a key supplier providing solid wood beams, decking timber, laminated veneer lumber (LVL), timber planks and log bundles for local construction, renovation and landscaping industries. Before the renovation, the client adopted traditional ground stacking to store long-length timber products. Random piling not only occupied over 70% of the warehouse floor space but also caused frequent timber warping, damp deformation and surface scratches due to direct contact with the ground. In addition, long timber bundles were difficult to access with forklifts, leading to low picking efficiency, prolonged inventory counting work and potential safety hazards caused by unstable stacked goods. Facing expanding business volume and growing order demands, the client urgently needed a tailored storage system to solve space waste, product damage and operational inefficiency. Combined with Australia’s local climate, warehouse environment and AS 4084-2012 industrial racking standards, we designed customized double-sided heavy-duty cantilever racks. The entire system is manufactured with high-tensile structural steel, equipped with reinforced uprights and thickened cantilever arms, delivering excellent load-bearing performance to bear heavy timber bundles steadily without deformation. All metal components adopt hot-dip galvanized surface treatment, which effectively resists corrosion, rust and moisture erosion, perfectly adapting to Australia’s humid outdoor and semi-outdoor timber yard environments and extending the service life. The adjustable arm height and spacing freely accommodate timber of different lengths, widths and specifications, realizing classified storage for various wood products. The open-front structure eliminates obstacles for forklifts and manual handling, enabling direct access to goods from both sides and greatly speeding up loading, unloading and delivery processes. After installation and commissioning, the client’s warehouse storage density increased by nearly 60%, and all timber is stored off the ground, thoroughly avoiding dampness, wear and warping. Daily picking and inventory efficiency improved dramatically, while standardized placement also optimized the overall working environment and reduced workplace safety risks. This cost-effective, durable and compliant cantilever racking system has fully met the client’s long-term storage and logistics demands, and won high recognition for its reliable quality, practical design and professional after-sales service. It has become a typical high-efficiency storage solution for local Australian timber and building material industries.

Project Overview: This case involves a drive-in industrial racking system customized for a leading logistics and warehousing company in Tashkent, Uzbekistan. The client, a key player in Central Asia’s cross-border trade and cargo distribution, specializes in storing and transporting bulk goods, including auto parts, construction materials, and consumer electronics—core commodities driving Uzbekistan’s economic growth. Facing the challenge of limited warehouse space and the need to optimize storage density for large-volume, low-SKU goods, the client sought a high-efficiency storage solution that could integrate with their existing forklift operations and adapt to the region’s industrial environment. After in-depth communication and on-site investigation of the client’s warehouse conditions, we designed and implemented a tailor-made drive-in racking system that perfectly meets their operational needs, significantly improving storage capacity and operational efficiency. Client Background: The client is a Tashkent-based logistics enterprise with over 8 years of experience in cross-border logistics and warehousing services, focusing on connecting Uzbekistan’s domestic market with Eurasian supply chains. As Uzbekistan accelerates the upgrading of its logistics infrastructure, the client’s warehouse (located in the Tashkent Logistics Park, a key hub for rail and road interconnection) has been facing increasing pressure from rising cargo volumes. Their existing storage system, mainly traditional selective racking, had low space utilization (only 45%), leading to high operating costs and inefficient cargo turnover. The client’s core requirements were to maximize storage density, reduce aisle space, ensure safe operation with heavy-duty loads, and align with international standards for durability and safety—critical for supporting their long-term business expansion in Central Asia. Client Requirements: After multiple rounds of communication, the client put forward clear and specific requirements for the drive-in racking system, based on their daily operations and cargo characteristics: • Storage Capacity: The warehouse has a total area of 1,200 square meters and a clear height of 8.5 meters; the client required the drive-in racking system to increase storage capacity by at least 50% compared to the existing selective racking, accommodating no less than 1,200 standard pallets. • Load Capacity: The main cargo stored includes auto parts (average 800kg per pallet) and light construction materials (average 1,000kg per pallet); thus, the racking system needed to support a uniform load capacity of 1,200kg per pallet position, with a maximum load capacity of 1,500kg per pallet to handle peak loads. • Pallet Specifications: The client uses the internationally standard 1200×1000mm pallets (the most common size in Uzbekistan’s cross-border trade), with a pallet height of 1500mm (including goods); the racking design needed to match this size and ensure smooth forklift entry and pallet placement. • Operational Efficiency: The system must follow the LIFO (Last-In, First-Out) principle, suitable for bulk goods with low turnover; forklift operation must be efficient, with clear guide structures to reduce collision risks and improve loading/unloading speed. • Durability & Safety: Given Uzbekistan’s dry and dusty industrial environment, the racking system needed to be made of high-strength steel with anti-corrosion treatment; additional safety accessories (column guards, guide rails, end stoppers) were required to protect the racking from forklift impact and prevent pallet slipping. • Certification & Compliance: The system must meet CE and CPR certifications to ensure compliance with international industrial safety standards, facilitating the client’s future expansion into other Eurasian markets. • Installation & After-Sales: The installation period must not exceed 15 days to minimize operational disruption; on-site training for the client’s operators and a 12-month after-sales maintenance service were required. Customized Solution Design: Based on the client’s requirements and on-site warehouse conditions, we designed a single-entry drive-in racking system (against the warehouse walls) with a scientific layout and optimized structural design, integrating industry best practices and regional adaptability: 1. Racking Structure & Dimensions: The system consists of 18 drive-in lanes, divided into 3 blocks (6 lanes per block) to ensure structural stability. Each lane is designed with a depth of 5 pallet positions (consistent with industry standards for 1,200kg/pallet loads, avoiding excessive depth that could affect forklift efficiency and safety). The racking height is 7.8 meters (reserving 0.7 meters of clear space for fire safety and ventilation), with 4 storage levels per lane. The upright frame depth is 1250mm (30mm more than the pallet width to accommodate slight pallet overhang), and the bay width is 1.2 meters, perfectly matching the client’s 1200×1000mm pallets. 2. Material & Load-Bearing Design: The racking components are made of high-strength Q235B cold-rolled steel, which has excellent load-bearing capacity and durability. The uprights adopt a 100mm section (suitable for racking heights over 6.5 meters), and the load beams are 120×50mm rectangular tubes, ensuring a uniform load capacity of 1,200kg per pallet position. All components are treated with hot-dip galvanizing and electrostatic spraying (RAL 7035 gray, the client’s specified color) to resist corrosion and dust, adapting to Uzbekistan’s industrial environment. 3. Safety Accessories: To ensure operational safety, the system is equipped with multiple safety components: column guards (installed at the bottom of each upright to prevent forklift impact), guide rails (installed along the inner sides of each lane to assist forklifts in centering and entering safely), end stoppers (installed at the end of each lane to prevent pallets from slipping due to gravity), and anti-collision buffers at the entrance of each lane. Additionally, the top beams and back bracing are reinforced to enhance the overall stability of the racking system, addressing the lower stability issue of drive-in racks compared to selective racks. 4. Operational Matching: The system is fully compatible with the client’s existing counterbalanced battery forklifts (the most commonly used forklift type in Uzbekistan’s warehouses). The main approach aisle width is designed to 3.5 meters, and the internal lane width is 1.2 meters, ensuring smooth forklift entry, loading, and retrieval operations. The LIFO operation mode is adopted, which is perfectly suited for the client’s bulk goods with low turnover, such as construction materials and auto parts. 5. Installation & Training: The installation team was dispatched to Tashkent within 3 days after the components were delivered to the client’s warehouse. The installation process strictly followed international standards, with on-site quality inspection at each step to ensure structural stability and safety. The entire installation was completed in 12 days, 3 days ahead of the scheduled period, minimizing the impact on the client’s normal operations. After installation, our technical team provided 2 days of on-site training for the client’s operators, covering forklift operation skills in the drive-in lanes, racking safety precautions, and daily maintenance methods. Project Implementation Results: After the completion of the drive-in racking system and a 3-month trial operation, the client achieved remarkable results, fully meeting and exceeding their expected goals: 1. Storage Capacity Improvement: The drive-in racking system increased the warehouse’s storage capacity from 800 pallets (with traditional selective racking) to 1,350 pallets, a 68.75% increase—far exceeding the client’s 50% growth requirement. The space utilization rate of the warehouse increased from 45% to 82%, maximizing the use of available floor space and vertical space, which is crucial for warehouses in high-logistics-cost areas like Tashkent. 2. Operational Efficiency Enhancement: The LIFO operation mode and optimized lane design reduced forklift travel distance by 40%, shortening the average loading/unloading time per pallet from 8 minutes to 4.5 minutes. The guide rails and safety accessories reduced forklift collision incidents by 100%, ensuring safe and efficient operations. The client’s daily cargo turnover increased by 35%, significantly improving their service capabilities for cross-border trade clients. 3. Cost Savings: The increase in storage density eliminated the need for warehouse expansion, saving the client approximately 200,000 USD in warehouse rental and expansion costs per year. The durable material and anti-corrosion treatment reduced the racking’s maintenance costs by 60% compared to traditional racking, further lowering operational expenses. 4. Compliance & Future Expansion: The system fully meets CE and CPR certifications, laying a solid foundation for the client’s future expansion into other Eurasian markets. The modular design of the racking allows for easy expansion—if the client’s cargo volume increases in the future, additional lanes or levels can be added without major modifications to the existing system. Client Feedback: “The customized drive-in racking system has completely solved our storage space and efficiency problems. The high storage density and safe operation have greatly improved our logistics service capabilities, allowing us to better meet the growing cross-border trade demand in Central Asia. The professional design, efficient installation, and thoughtful after-sales service have exceeded our expectations, and we look forward to continuing our cooperation for future warehouse upgrading projects.” — Logistics Director of the Uzbekistan Client Project Summary: This drive-in industrial racking project for the Uzbekistan client fully demonstrates the value of high-density storage solutions in solving the pain points of limited warehouse space and low efficiency. By combining the client’s specific operational needs, cargo characteristics, and regional industrial environment, we designed a tailor-made solution that not only meets the basic storage and load-bearing requirements but also considers long-term operational efficiency, safety, and compliance. The success of this project not only strengthens our cooperation with clients in Uzbekistan but also provides a professional reference for drive-in racking applications in Central Asia’s cross-border logistics and warehousing industry, helping local enterprises optimize their storage systems and enhance their competitiveness in the Eurasian supply chain.

Client Background: Established in 2008, Greenfield Logistics Ltd is a well-known third-party logistics provider settled in Manchester Trafford Park, UK, specializing in FMCG stock storage, e-commerce order picking and nationwide distribution for UK local supermarket chains and online retail brands. By early 2025, the firm faced severe warehouse space shortage: their 3,200㎡ single-story warehouse reached full stock saturation, daily inbound pallet cargo kept rising with peak holiday season coming, while factory reconstruction and new warehouse leasing would cost over 35% extra annual operating expense and need 3–5 months vacant period, which could not match their fast-growing order volume. After comparing multiple domestic UK racking suppliers, Greenfield chose our company to customize full-set rack-supported steel mezzanine platform solution for vertical space upgrading. Project Design & Core Technical Parameters: We completed on-site survey, structural calculation and UK building regulation compliance design within 7 working days in accordance with UK Part B fire safety standard and local industrial storage load specification. The whole mezzanine covers total usable area of 1,420㎡, single-layer platform height set at 3.65m, rated uniform floor load capacity 500kg per square meter for daily carton picking and pallet temporary storage. The platform adopts rack-supported integrated structure, using standard bolted selective pallet rack uprights plus welded step beams (your core hot-selling welded step beam products) as main load-bearing frame instead of independent heavy steel columns, which greatly saves ground aisle space and reserves full forklift access on ground floor. Ground floor is equipped with standard selective pallet racking for bulk palletized finished goods storage; upper mezzanine floor lays anti-slip high-density particle board decking, matched with 1100mm-height yellow powder-coated safety guardrails, two sets of dual-flight industrial anti-slip steel staircases and 2 automatic safety pallet drop gates for forklift pallet loading/unloading from ground to upper floor. All steel components go through pickling, phosphating and electrostatic epoxy powder coating to resist UK humid industrial warehouse corrosion, fully pass UK local third-party load test and fire rating inspection before delivery. Production, Shipment & On-site Installation: All structural steel frames, uprights, welded step beams, platform deck accessories were finished production within 22 working days at our factory, loaded into 4×40HQ containers and shipped to Liverpool Port then inland trucked to Manchester warehouse smoothly. Our professional overseas installation team arrived on-site, split construction into 3 phases to avoid full warehouse shutdown and stop client’s normal daily warehousing operation; total on-site assembly and installation took only 18 calendar days and finished ahead of pre-agreed delivery deadline. Post-installation Operational Benefits & Client Feedback: After official acceptance, Greenfield Logistics gained an extra 1,420㎡ usable storage area without expanding original warehouse building or changing factory exterior structure, effectively lifting overall warehouse storage capacity by nearly 52%. Ground floor bulk pallet storage plus upper mezzanine small-batch SKU picking layout optimized internal material circulation route, average daily order picking efficiency improved by around 38%, annual warehouse rent and factory expansion cost saved more than £78,000. In mid-year follow-up email, the client commented our mezzanine solution cost-effective, stable load performance and full compliance with UK industrial safety codes, and signed a repeat order of 960㎡ secondary small mezzanine expansion project for their Leeds branch warehouse in the third quarter of 2025, also introducing 3 local UK logistics partners to consult our steel platform and pallet racking solutions. This mature UK installation case has become our typical European mezzanine rack reference project for new customer development.

1. Project Overview & Client Background This complete practical case study focuses on a successful warehouse upgrading project implemented by Nanjing Peter Storage Equipment, a professional storage racking manufacturer with over 10 years of production and export experience, for a large-scale textile manufacturing enterprise based in Faisalabad, Pakistan. Faisalabad is known as the “Textile Capital of Pakistan”, hosting countless spinning, weaving, printing and dyeing factories, and undertaking most of the country’s textile export business. The client is a local leading integrated textile enterprise, mainly engaged in the production, processing and export of various textiles, including cotton fabric, polyester fabric, blended fabric, yarn rolls and finished textile rolls. Its products are exported to Europe, the Middle East, Southeast Asia and other regions, with stable and large annual export volume. The client owns a professional textile raw material warehouse covering 5200 square meters, specially used for storing various bulk fabric rolls and yarn materials. Textile fabrics are soft, high-value, moisture-sensitive and scratch-prone materials, which require dry storage environment, flat placement, anti-extrusion protection and classified batch management. With the continuous expansion of the client’s production and export business in recent years, the inventory of various fabrics has increased year by year. The original traditional fixed selective racking can no longer meet the growing storage demand, resulting in insufficient warehouse space, disorderly fabric placement, low access efficiency and frequent material waste. To solve these bottlenecks and upgrade the warehouse storage system, the client finally chose our customized motorized mobile racking system to realize high-density, standardized and intelligent storage of textile fabrics. 2. Traditional Warehouse Storage Challenges & Pain Points Before the renovation, the client’s warehouse adopted conventional fixed pallet racking with independent operation aisles reserved between each group of racks. Combined with the storage characteristics of textile fabric rolls and the local industrial environment of Pakistan, the traditional storage mode exposed many unavoidable problems, which seriously restricted the enterprise’s production and warehousing efficiency. First, serious waste of warehouse space and insufficient storage capacity. Fixed racking requires a large number of fixed forklift operation aisles, which occupy more than 45% of the total warehouse area. Most of the warehouse space cannot be effectively utilized. Textile fabric rolls are bulky and diverse in specifications, resulting in limited single-layer storage volume. With the continuous increase of fabric orders, the original warehouse capacity was severely insufficient. The client had to stack part of the fabrics on the ground or rent additional small warehouses, which not only increased extra rental and handling costs, but also caused scattered inventory and difficult unified management. Second, easy damage and moisture deterioration of high-value fabrics. Fabrics stacked on the ground were prone to extrusion deformation, surface friction and yarn loosening. Pakistan has a humid and hot seasonal climate, and ground stacking makes fabrics directly affected by ground moisture, leading to mildew, color difference and damp damage. In addition, the disorderly placement of different types of fabrics caused frequent scratching and pollution during manual handling and picking, resulting in economic losses and affecting the quality of finished textile products for export. Third, low picking efficiency and chaotic inventory management. The traditional fixed racking layout was scattered, with mixed placement of different specifications, colors and batch fabrics. Warehouse staff needed to spend a lot of time searching and sorting materials every day. The manual picking error rate was high, and the overall material access efficiency was low. It was impossible to realize accurate batch management of incoming and outgoing fabrics, which could not match the client’s fast-paced production and export delivery cycle. Fourth, high labor cost and low warehouse utilization flexibility. The fixed racking structure cannot be adjusted according to inventory changes. During the peak production season, the warehouse was extremely crowded, while the off-season had redundant idle space. The long-term manual sorting and handling increased labor input, resulting in high comprehensive warehousing costs and poor overall operational flexibility. 3. Customized Motorized Mobile Racking Solution for Textile Storage According to the client’s warehouse size, fabric storage characteristics, local climate conditions and actual operational pain points, our professional engineering team designed acustomized heavy-duty motorized mobile racking system specially suitable for textile fabric roll storage. Different from ordinary fixed racks, the electric mobile racking cancels multiple fixed redundant aisles. All rack groups are installed on electric mobile base rails, which can automatically move left and right through the motor drive system. Only one working aisle is reserved according to operational needs, which greatly improves the warehouse space utilization and fully adapts to the high-density storage demand of textile fabrics. The whole set of racking is made of high-quality Q235 national standard steel, with automatic robotic welding technology and high-standard electrostatic anti-rust and anti-corrosion spraying surface treatment. It has strong compression resistance, deformation resistance, moisture-proof and dust-proof performance, which can well adapt to the hot and humid storage environment in Pakistan and effectively protect high-value textile fabrics from moisture and damage. The bottom is equipped with silent mobile tracks and stable motor drive devices, with stable operation, low noise and strong load-bearing capacity. The core design parameters of the project are as follows: The overall racking height is 6.8 meters, with 4 storage layers, equipped with 8 sets of independent electric mobile racking units. The system reserves only one adjustable working aisle, reducing redundant aisle space by more than 60%. It supports electric one-key movement and remote control operation, with a total of 3200 standard storage positions, fully meeting the client’s large-scale fabric roll storage demand. The beam spacing is flexibly customized according to the diameter and length of common fabric rolls, avoiding extrusion and friction between fabrics. At the same time, we added anti-collision induction devices and emergency stop buttons for each mobile unit to ensure 100% safety during equipment operation. In terms of functional design, this mobile racking system supports classified storage of different fabrics. Cotton fabrics, polyester fabrics, blended fabrics and yarn rolls are placed in different areas, realizing standardized classification management. The electric mobile operation mode can flexibly open the corresponding operation aisle according to the picking and warehousing requirements, which is convenient for forklift and manual access, greatly improving the flexibility and efficiency of material handling. 4. Project Production & On-Site Implementation After the design scheme was confirmed by the client, our factory started standardized production in strict accordance with international storage equipment standards and Pakistani local safety specifications. All steel materials underwent strict raw material inspection, welding quality inspection and surface treatment testing to ensure the stability and durability of the equipment. The motor drive system adopts high-quality industrial dedicated motors, with stable power, long service life and low failure rate, adapting to long-term high-frequency operation. All equipment production and factory inspection were completed within 40 working days. After passing the quality test, the goods were packed in export-standard wooden cases and shipped to Karachi Port, Pakistan. With the cooperation of our long-term cooperative local agent, we completed customs clearance, transportation and warehouse entry efficiently and smoothly. Subsequently, our professional installation team rushed to the client’s warehouse for on-site assembly, track laying, equipment debugging and safety testing. During the installation and commissioning stage, we completed the fixed laying of the bottom track, the overall assembly of the rack body, the wiring debugging of the motor system and the induction test of safety protection devices. After the installation was completed, we conducted multiple full-load operation tests, mobile sensitivity tests and safety emergency stop tests to ensure that all equipment operates stably and meets the design standards. In addition, we provided free professional training for the client’s warehouse managers and operators, including equipment operation specifications, daily maintenance methods, fault judgment and processing, and fabric storage management skills, to ensure that the client’s team can proficiently use and maintain the new system. 5. Post-Project Operation Effects & Core Improvements After the official operation of the motorized mobile racking system, the client’s textile warehouse has achieved comprehensive upgrading in storage capacity, material protection, operational efficiency and cost control, and all traditional storage pain points have been completely solved. First, the warehouse space utilization rate has been greatly improved. By canceling multiple fixed aisles and adopting flexible mobile operation, the warehouse space utilization rate has increased by more than 65%, and the total fabric storage capacity has nearly doubled. It fully meets the client’s peak inventory storage demand, completely eliminates the need for external warehouse leasing, and saves a large amount of annual rental, transportation and management costs for the enterprise. Second, the fabric damage and deterioration rate is effectively controlled. The standardized layered storage avoids fabric extrusion and friction damage. The dry and tidy storage environment matched with the moisture-proof performance of the racking equipment completely solves the problems of mildew and damp damage of fabrics caused by ground stacking. The client’s fabric damage rate has dropped from the original 7% to less than 1%, effectively protecting high-value textile raw materials and ensuring the quality of export products. Third, the warehouse operation efficiency is significantly improved. The electric one-key mobile design realizes fast switching of operation aisles, and the classified storage mode makes fabric picking and warehousing more accurate and efficient. The material search time is shortened by 70%, the overall access efficiency is increased by more than 60%, and the manual picking error rate is almost zero, which greatly matches the client’s efficient production and export delivery rhythm. Fourth, the warehouse management is standardized and safer. The intelligent mobile racking system realizes unified classification and batch management of all textile fabrics, with clear inventory and real-time controllable quantity. Equipped with perfect anti-collision and emergency stop safety devices, the equipment operation risk is extremely low, eliminating safety hazards such as rack collision and material collapse in traditional warehouses. The standardized operation also reduces labor investment and reduces long-term warehousing management costs. 6. Client Feedback & Project Summary The client spoke highly of the effect of this electric mobile racking textile storage project. They said that Nanjing Peter’s customized solution perfectly solved their long-standing problems of insufficient warehouse space, easy fabric damage and low operational efficiency. The motorized mobile racking system is flexible in operation, stable in performance, durable and easy to maintain, which is very suitable for high-density storage of high-value textile fabrics in Pakistan’s textile industry. At present, the client’s warehouse operates stably and efficiently all year round, the inventory management level has been comprehensively improved, and the product export qualification rate has been further increased, bringing more stable economic benefits to the enterprise. Meanwhile, the client has established long-term strategic cooperative relations with our company for subsequent warehouse expansion and supporting equipment customization projects. This project fully verifies that motorized mobile racking systems are the optimal storage solution for high-value, moisture-prone and specification-diversified materials such as textile fabrics, yarn rolls and leather materials. It has prominent advantages of high space utilization, flexible operation, safe storage and low loss, and is widely applicable to textile factories, garment factories and raw material warehousing enterprises in Pakistan, Central Asia and South Asia. With rich overseas project experience and professional customized design capability, Nanjing Peter always provides cost-effective, stable and durable warehouse storage solutions for global industrial and commercial customers, helping customers reduce warehousing costs and improve operational efficiency.

The case study focuses on FreshPro Australia Pty Ltd, a leading mid-sized food distributor headquartered in Melbourne, Victoria, with over 15 years of experience supplying ambient, chilled, and frozen food products to supermarkets, convenience stores, and food service providers across Australia’s eastern seaboard. The company manages a diverse inventory including packaged dry goods, dairy products, fresh produce, frozen meats, and ready-to-eat meals, serving more than 300 retail and hospitality clients daily. Prior to 2022, FreshPro operated out of a 6,200 m² conventional warehouse in Brisbane, Queensland, equipped with standard selective pallet racking and limited cold storage zones. As the Australian food retail sector expanded—driven by post-pandemic demand for consistent food supply, growth in online grocery shopping, and stricter food safety regulations—the company faced critical operational bottlenecks that threatened its ability to scale. The existing warehouse suffered from severe space constraints, inefficient inventory rotation, high labor costs, and inconsistent temperature control, which directly impacted product quality, order fulfillment speed, and profit margins. Core Challenges Before Implementation Insufficient Storage Density & Wasted Space Traditional selective pallet racking required wide forklift aisles (3.5–4 meters) and only utilized 35–40% of the warehouse’s vertical and floor space. With inventory volumes growing by 28% year-over-year, FreshPro was forced to rent additional off-site storage, incurring AUD 120,000 annually in extra rental and transportation costs. The fragmented storage layout also led to 15–20 minutes of forklift travel time per pallet movement, drastically reducing operational efficiency. Non-Compliant Inventory Rotation (FIFO Failure) The food industry demands strict First-In-First-Out (FIFO) inventory management to minimize food waste and comply with Australia’s Food Safety Standards (FSANZ). Manual operations and disorganized racking made FIFO enforcement nearly impossible: 8–10% of perishable goods (e.g., dairy, fresh produce) expired before distribution, costing FreshPro approximately AUD 85,000 annually in write-offs. Additionally, 3–5% of orders were shipped with expired or near-expiry products, leading to client complaints and potential regulatory penalties. High Labor Costs & Safety Risks The warehouse relied on 12 full-time forklift operators and 8 pickers for daily operations. Forklifts entering deep storage aisles increased the risk of collisions with racking, pallets, or personnel—resulting in 3–4 minor workplace accidents per year and rising insurance premiums. Manual pallet handling (average weight 25–30 kg) also led to repetitive strain injuries, with 2–3 workers taking medical leave annually, further disrupting operations and increasing labor costs. Inefficient Cold Storage & High Energy Consumption FreshPro’s cold storage zones (1°C–4°C for chilled goods, -18°C–22°C for frozen products) used traditional racking, which required frequent forklift entries and exits. This caused thermal leakage—warm air entering the cold zones and cold air escaping—leading to inconsistent temperature control (±2°C) and 30% higher energy bills than industry benchmarks. Inconsistent temperatures compromised product quality, particularly for frozen meats and fresh produce, increasing the risk of spoilage. Lack of Inventory Traceability Manual record-keeping and barcode scanning errors resulted in 7–9% inventory inaccuracy, making it difficult to track product batches, expiration dates, or recall items quickly. This violated FSANZ’s traceability requirements and put FreshPro at risk of non-compliance during food safety audits. Solution Selection: Customized Shuttle Racking System After evaluating multiple storage solutions—including drive-in racking, push-back racking, and automated AS/RS systems—FreshPro partnered with Nanjing Peter Storage Equipment Co., Ltd. (a professional shelving manufacturer with 10+ years of production and export experience) to design and install a customized pallet shuttle racking system tailored to its food storage needs. The solution was selected for its high storage density, semi-automated operation, FIFO compliance, cold storage compatibility, and cost-effectiveness compared to fully automated systems. System Design & Key Specifications The shuttle racking system was installed in a newly built 8,500 m² warehouse in Brisbane, Queensland, completed in late 2022. The design focused on optimizing space, ensuring food safety, and integrating with FreshPro’s existing Warehouse Management System (WMS). Key specifications include: Racking Structure: Heavy-duty steel racking (Q235 grade, compliant with Australian Standard AS 4084) with a height of 10.5 meters, featuring 8 storage levels and 12 narrow aisles (1.6 meters wide) for shuttle cart operation. The system includes 6,800 pallet positions (1,200mm × 1,000mm standard pallets, max load 1,500 kg per pallet). Shuttle Carts: 16 lithium-ion battery-powered shuttle carts (48V LiFePO4 batteries, 8–12 hours of continuous operation per charge) with remote control and WMS integration. The shuttles operate on dedicated steel rails within the racking lanes, enabling automatic pallet storage, retrieval, and horizontal movement. Battery swapping takes less than 60 seconds, ensuring 24/7 operation for peak demand. 物流 穿梭车货架 shuttle cart Temperature Zones: The system is divided into three integrated zones: Ambient zone (15°C–25°C) for dry goods (packaged snacks, grains, canned foods) – 3,200 pallet positions. Chilled zone (1°C–4°C) for dairy, fresh produce, and ready-to-eat meals – 2,100 pallet positions. Frozen zone (-18°C–22°C) for meats, seafood, and frozen vegetables – 1,500 pallet positions.

1. Project Overview & Client Background This practical case study highlights a successful warehouse storage upgrade project completed by our company (Nanjing Peter Storage Equipment) for a leading local agricultural supply and cold chain enterprise based in Kabul, Afghanistan. The client is a major regional supplier and wholesaler of staple crops, specializing in large-scale potato purchasing, fresh preservation, seasonal stock storage, and bulk distribution to local supermarkets, rural markets, food processing factories, and government food reserve programs across Afghanistan. Potatoes are one of the most essential staple foods in Afghanistan with huge annual consumption and seasonal harvesting characteristics. Every year from September to November is the local potato harvest season, requiring massive short-term warehousing and long-term fresh storage to avoid market shortages and price surges in off-seasons. Before cooperating with us, the client adopted a traditional bulk stacking storage method and simple selective pallet racks to store fresh potatoes. The original warehouse was a 4800 square meters indoor constant-temperature warehouse with basic ventilation and moisture-proof equipment, designed specifically for root vegetable storage. However, the outdated storage mode brought multiple severe operational problems, including extremely low space utilization, serious potato spoilage, chaotic inventory management, high labor costs, and inability to cope with seasonal peak storage pressure. To solve these long-term pain points and standardize potato storage management, the client decided to fully renovate the warehouse storage system and finally chose our heavy-duty drive-in racking system as the core storage solution for bulk potato inventory. 2. Original Warehouse Problems & Storage Pain Points Afghanistan’s local climate is dry with large temperature differences between day and night, and fresh potatoes are extremely sensitive to storage environment, requiring stable ventilation, fixed stacking height, low extrusion pressure, and batch inventory management. The client’s original storage mode could not meet professional potato preservation standards, with the following prominent problems: First, extremely low warehouse space utilization. The previous selective pallet racking required multiple wide operation aisles for forklift access, occupying nearly 40% of the entire warehouse area. A large number of valid storage spaces were wasted, and the original warehouse could only store a maximum of 1800 pallets of potatoes. In the peak harvest season, the client had to rent multiple temporary simple warehouses outdoors, which greatly increased additional rental costs, handling costs, and transportation risks. The scattered storage sites also made unified inventory management impossible. Second, serious potato extrusion damage and spoilage loss. The traditional manual bulk stacking method had no fixed layered support structure. Potatoes at the bottom bore huge extrusion pressure, leading to frequent bruising, cracking and rot. Moreover, manual random stacking blocked internal air circulation, causing local damp and mildew in the middle and lower layers of potato stacks. Before the renovation, the client’s annual potato spoilage and damage rate remained as high as 8%–12%, resulting in huge economic losses and greatly affecting the quality of supplied goods. Third, disordered inventory and unable to implement batch management. Potato storage has strict batch management requirements. Potatoes harvested in different periods have different freshness and shelf life, requiring strict LIFO (Last In First Out) management for batch delivery. The original storage mode mixed all batches of potatoes together, making it impossible to distinguish production batches and storage time. It was easy to cause long-stored potatoes to be overstocked and deteriorated, while newly harvested potatoes were delivered first, forming a vicious cycle of inventory backlog. Fourth, low operational efficiency and high safety risks. The scattered stacking and disorderly aisles led to slow forklift loading and unloading speed, requiring a large number of workers to sort and handle goods every day. The labor cost remained high all year round. In addition, irregular manual stacking was prone to collapse accidents, bringing great safety hazards to warehouse personnel and equipment. 3. Customized Solution: Heavy-Duty Drive-In Racking System After fully investigating the client’s warehouse site size, potato storage characteristics, annual inventory volume, local climate environment and budget, our professional engineering team customized a high-density, heavy-load, ventilation-optimized drive-in racking system suitable for bulk potato storage. Different from ordinary industrial racks, this set of racking was specially optimized for the storage characteristics of fresh potatoes and the harsh local storage environment in Afghanistan. The overall racking system adopts national standard Q235 hot-rolled steel raw materials, with full automatic robotic welding and high-strength electrostatic spray anti-corrosion treatment. It is moisture-proof, rust-proof, wear-resistant and pressure-resistant, adapting to the dry and temperature-changing storage environment in Kabul. The whole system cancels redundant operation aisles, adopts integral continuous racking lane design, allowing forklifts to directly drive into the racking interior for pallet loading and unloading, maximizing the utilization of warehouse vertical and horizontal space. The key design parameters of the project are as follows: The total racking height is 7.2 meters, with 4 storage layers, 12 main storage lanes, and a total of 3900 standard pallet storage positions. Each pallet is designed with a rated load of 1200KG, fully meeting the weight demand of bulk packaged potatoes. The supporting guide rails are thickened and reinforced to ensure stable bearing and no deformation after long-term heavy load operation. Meanwhile, we reserved uniform ventilation gaps between the racking beams and pallet positions, which effectively accelerates air circulation inside the warehouse, avoids damp and mildew of potatoes, and greatly improves the fresh-keeping effect of bulk potatoes. In terms of operation mode, the drive-in racking system perfectly matches the client’s potato batch storage demand, adopting standard LIFO (Last In First Out) inventory mode. Newly warehoused potatoes are stored in the innermost part of the racking lane, and goods are taken from the outermost position during delivery. This mode is completely suitable for the client’s seasonal centralized warehousing and long-term batch delivery business, realizing standardized batch management of potato inventory. 4. Project Implementation & Installation Process The whole project was completed in strict accordance with international warehouse storage standards and Afghan local warehouse safety specifications, including site measurement, scheme design, factory production, quality inspection, international transportation, on-site installation and after-sales training. Our team completed all production and delivery work within 45 working days. After the goods arrived at Kabul port, we cooperated with local formal agents to complete customs clearance and transportation efficiently. During the on-site installation period, our professional construction team strictly followed the warehouse layout plan to complete the overall assembly, fixed reinforcement, level calibration and safety testing of the drive-in racking. After the installation was completed, we conducted multiple heavy-load pressure tests, forklift access simulation tests and ventilation effect tests to ensure that all indexes of the racking system met the design standards. At the same time, we provided free professional operation training for the client’s warehouse management personnel and forklift drivers, including standard loading and unloading procedures, daily racking maintenance, safety operation specifications and inventory management skills, to ensure the stable and efficient operation of the new system. 5. Project Operational Effects & Core Advantages After the official put into use of the drive-in racking system, the client’s potato warehouse storage capacity, fresh-keeping effect, operational efficiency and cost control have been comprehensively improved, solving all the previous storage pain points, and the overall warehouse management has achieved standardized upgrading. First, the warehouse storage capacity has been greatly improved. By canceling redundant aisles and making full use of three-dimensional space, the space utilization rate of the client’s warehouse has increased by more than 75%, and the total potato storage capacity has increased from the original 1800 pallets to 3900 pallets. It fully meets the peak storage demand during the potato harvest season, completely eliminates the need for temporary external warehouse leasing, and saves the client a lot of annual rental and transportation costs. Second, the potato spoilage rate is greatly reduced. The standardized layered storage of the drive-in racking avoids excessive extrusion of potatoes, and the reserved ventilation gaps ensure smooth air circulation in the warehouse. The potato extrusion damage rate and mildew spoilage rate have dropped from the original 8%–12% to less than 2%, which greatly reduces commodity loss and improves the client’s product qualification rate and market competitiveness. Third, inventory management is standardized and efficient. The LIFO operation mode realizes scientific batch management of potatoes, effectively avoids inventory backlog and long-term storage deterioration, ensures that the delivered potatoes are always fresh with stable quality, and greatly improves customer satisfaction. Fourth, operational costs are reduced and warehouse safety is improved. The centralized and orderly racking layout simplifies the forklift operation process, improves the loading and unloading efficiency by more than 60%, and greatly reduces labor investment and time cost. The overall fixed and reinforced racking structure eliminates the risk of goods stacking collapse, realizing safe and standardized warehouse operation. 6. Client Feedback & Project Summary The client highly recognized the overall effect of the drive-in racking potato storage project. They stated that our customized high-density storage solution completely solved their long-standing problems of insufficient warehouse capacity, serious potato loss and chaotic management. The racking system is sturdy and durable, easy to operate and convenient for daily maintenance, which is very suitable for large-scale bulk storage of agricultural products such as potatoes in Afghanistan. At present, the client’s warehouse has achieved stable and efficient operation, with continuous improvement of economic benefits, and they have reached a long-term cooperative intention with our company for subsequent warehouse expansion projects. This project fully proves that drive-in racking systems are the most ideal storage solution for bulk agricultural products such as potatoes, onions and other root vegetables. It has the advantages of high density, large capacity, low loss, low cost and easy management, and is especially suitable for food warehousing enterprises and agricultural product reserve warehouses in Central Asia and Middle East regions with seasonal concentrated warehousing demand. As a professional warehouse racking manufacturer with more than 10 years of export experience, Nanjing Peter has rich project experience in customized storage solutions for special industries and regional environments, providing reliable, cost-effective and long-lasting warehouse storage equipment and one-stop services for global customers.