Nanjing Peter Logistics Equipment Co., Ltd.

Forklifts don’t apologize—guardrails do the protecting. In a warehouse, one “oops” from a driver can cost thousands. A guardrail costs far less. That’s why we use high-strength steel barriers in bright yellow or black: Block forklift impact Protect rack uprights and workers Separate people from machines Keep dangerous zones off-limits At Nanjing Peter Logistics Equipment Co., Ltd., we customize guardrails for aisles, walkways, and critical areas in warehouses worldwide. Be honest—has a forklift ever “kissed” your rack before?

Ever had a pallet give up on life and drop everything? Yeah… gravity doesn’t care about your inventory. That’s why wire mesh decking is a warehouse lifesaver: Catches falling goods when pallets fail Holds 200–1,000 kg with no complaints Installs with zero tools—just drop it in place Helps with fire safety, airflow, and lighting We customize mesh decking to fit different rack sizes and load needs at Nanjing Peter Logistics Equipment Co., Ltd. Be honest—has anything ever “jumped” off your rack?

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.

Gravity Racks: Automatic and Efficient Storage Flow Ever wondered how to speed up order picking? Gravity racks use roller lanes with a slight slope, letting pallets move automatically by gravity — achieving true FIFO (First-In, First-Out).  Technical Benefits:• Efficiency: fewer aisles, faster operations.• Smart: compatible with automation systems.• Safety: rollers with damping to prevent impact.• Capacity: up to 1000kg per pallet.  Why choose Nanjing Peter Logistics Equipment Co. Ltd? We customize slope, roller type, and braking devices to fit your warehouse. Our gravity racks have been successfully exported to Australia, Chile, and UAE, helping clients maximize turnover and storage efficiency.

Client Background Our client is a leading cold chain logistics enterprise in East China, specializing in the storage, processing, and distribution of frozen food, dairy products, and fresh produce. With a rapidly expanding business scale, the company’s original warehouse faced severe challenges: low space utilization (less than 40%), scattered inventory storage, high energy consumption in cold storage, and inability to meet the growing demand for high-volume, homogeneous goods storage. The client urgently needed a high-density storage solution to optimize warehouse space, improve operational efficiency, and reduce long-term operation costs. After in-depth market research and technical comparison, the client finally chose our customized drive-in racking system as the core solution for warehouse upgrading. Project Overview Basic Information Project Location: Nanjing, Jiangsu Province, China Warehouse Type: Low-temperature cold storage (constant temperature -18°C) Warehouse Area: 8,000 square meters Racking Type: Heavy-duty galvanized drive-in racking (food-grade anti-corrosion treatment) Racking Specifications: 6 layers high (total height 12 meters), 8 pallets deep per lane, 24 storage lanes in total Pallet Parameters: Standard 1200mm×1000mm plastic pallets, single pallet load capacity 1.5 tons Total Storage Capacity: 11,520 pallet positions (3.6 times the original storage capacity) Core Project Goals Maximize warehouse space utilization, increase storage capacity by more than 200%. Adapt to the low-temperature and high-humidity environment of cold storage, ensuring the long-term stability and anti-corrosion performance of the racking. Simplify inventory management, realize "first-in, last-out" batch storage for homogeneous goods, and improve the efficiency of forklift access operations. Reduce the loss of cold air in the warehouse, lower energy consumption for refrigeration, and achieve cost-saving and emission-reduction goals. Ensure the safety and compliance of the racking system, meeting national heavy-duty racking safety standards and cold storage industry specifications. Key Challenges & Pre-Installation Preparation Main Challenges Harsh Environment Adaptability: The cold storage operates at -18°C with high humidity, which requires the racking to have excellent anti-corrosion, anti-rust, and low-temperature resistance capabilities; ordinary carbon steel racking is prone to rust and deformation in this environment. High-Density Structural Stability: The racking is 12 meters high and 8 pallets deep, which puts forward high requirements for the structural stability, load-bearing capacity, and seismic performance of the racking; any structural defect may lead to safety hazards such as racking collapse. Precision Installation Requirements: The installation accuracy of drive-in racking is extremely high. The verticality deviation of columns, the levelness deviation of support rails, and the alignment deviation of guide rails directly affect the safety of forklift entry and the stability of pallet storage. Construction Period Constraints: The client’s business cannot be interrupted for a long time, and the installation and debugging must be completed within 25 days to ensure the normal operation of the cold storage during the peak sales season. Pre-Installation Preparation Work On-Site Survey & Customized Design: Our engineering team conducted a 3-day detailed on-site survey, including warehouse floor flatness, bearing capacity, wall structure, ceiling height, and the position of refrigeration equipment. Combined with the client’s pallet size, load weight, and inventory characteristics, we used 3D modeling software to design a personalized drive-in racking scheme. The scheme optimizes the lane spacing and support rail structure, and adopts a reinforced brace design to enhance the longitudinal rigidity and seismic performance of the racking, fully adapting to the low-temperature environment and high-density storage needs. Material Selection & Quality Control: In terms of material selection, we use high-quality Q235B carbon steel as the main material of the racking, with the surface treated by hot-dip galvanizing (galvanized layer thickness ≥ 85μm), which has excellent anti-corrosion and anti-rust performance and can adapt to the long-term low-temperature and high-humidity environment. All materials are strictly tested for tensile strength, yield strength, and impact toughness before leaving the factory, and the welding parts are inspected by non-destructive testing to ensure that each component meets national standards and project quality requirements. Installation Plan Formulation & Safety Training: We formulated a detailed phased installation plan, dividing the project into four stages: foundation treatment, component installation, guide rail debugging, and system acceptance, with clear tasks and time nodes for each stage. Before construction, we conducted 2 rounds of safety and technical training for all installation personnel, focusing on the installation specifications of high-altitude operations, the use of professional tools, and the anti-freezing and anti-slip measures in low-temperature environments, ensuring that each installer is familiar with the operation process and safety precautions. Auxiliary Equipment & Site Layout: We prepared professional installation equipment suitable for low-temperature environments, such as electric hoists, high-altitude operation platforms, and laser levelers, and carried out anti-freezing treatment for the equipment. At the same time, we rationally planned the on-site material stacking area, installation operation area, and forklift passage to avoid interference between different operations and ensure the smooth progress of the installation work. Detailed Installation Process & Key Technical Points Stage 1: Foundation Treatment & Column Base Installation (Days 1-5) The flatness and bearing capacity of the warehouse floor are the foundation for the stable operation of the drive-in racking. First, the construction team used a laser leveler to conduct a comprehensive inspection of the warehouse floor, and polished and leveled the uneven areas to ensure that the floor flatness deviation is controlled within ±3mm/m. Then, according to the design drawing, the anchor bolt positions are accurately marked on the floor, and the foundation holes are drilled with a professional drilling rig. After cleaning the dust and debris in the holes, high-strength non-shrinkage grout is poured, and the column bases are placed and fixed. During the installation of the base, the verticality of the base is strictly controlled with a level, and the horizontal deviation of all bases in the same row is guaranteed to be less than 5mm, laying a solid foundation for the subsequent installation of columns and beams. Stage 2: Column & Main Frame Installation (Days 6-15) This stage is the core link of the entire installation project, which directly determines the structural stability and safety of the racking. First, the pre-galvanized columns are hoisted to the corresponding bases by an electric hoist, and the columns are connected and fixed with the bases through high-strength bolts. During the hoisting process, professional constructors hold the columns to avoid collision with the warehouse wall or other equipment. After the columns are installed, the verticality of each column is checked with a theodolite, and the verticality deviation is adjusted to be less than 10mm/12m by tightening or loosening the fixing bolts. Next, the main beams and diagonal braces are installed between the columns. The main beams are connected with the columns through high-strength bolts, and the diagonal braces are installed in a triangular distribution to enhance the longitudinal and lateral stability of the racking frame. After the installation of the main frame, the overall dimension of the frame is measured, and the spacing deviation between adjacent columns is controlled within ±5mm to ensure the accurate installation of the subsequent support rails and guide rails. In the low-temperature environment of -18°C, the construction team took anti-slip measures such as wearing anti-slip gloves and shoes, and shortened the continuous operation time to avoid safety accidents caused by low-temperature frostbite. Stage 3: Support Rail & Floor Guide Rail Installation (Days 16-22) The support rail is the key component for supporting pallets, and its installation accuracy directly affects the stability of pallet storage and the safety of forklift access. The support rail adopts a triangular galvanized steel structure, which is installed on both sides of each layer of the racking lane. During installation, the levelness of the support rail is adjusted with a laser leveler, and the levelness deviation of the same layer of support rail is controlled within ±3mm. At the same time, the distance between the support rails on both sides is strictly controlled according to the pallet width to ensure that the pallets can be accurately placed on the support rails without shaking or tilting. The floor guide rail is installed at the bottom of each storage lane, which plays a guiding role for the forklift to enter and exit the lane, preventing the forklift from colliding with the racking and causing damage. The guide rail is made of high-strength galvanized steel, which is fixed on the warehouse floor with expansion bolts. During installation, the straightness of the guide rail is adjusted with a laser theodolite, and the deviation is controlled within ±5mm/10m. At the end of the guide rail, a centering device is installed to assist the forklift in accurately entering the storage lane. After the installation of the support rail and guide rail, the construction team conducted a trial run with a forklift to simulate the process of pallet entry and exit, and adjusted the positions of the support rail and guide rail in time according to the trial run situation to ensure the smoothness and safety of the access operation. Stage 4: Overall Debugging & Safety Inspection (Days 23-25) After the installation of all components is completed, the engineering team carried out a comprehensive overall debugging and safety inspection of the drive-in racking system. First, the structural stability of the racking is inspected, including checking whether all bolts are tightened, whether the welding parts are firm, and whether the columns, beams, and braces are deformed or damaged. Then, the load-bearing test is carried out: standard pallets with a load of 1.5 tons are placed on each layer of the support rails, and the deformation of the support rails and the settlement of the columns are observed after 24 hours of loading. The test results show that the deformation of all support rails is less than 2mm, and the column settlement is less than 1mm, which meets the design load-bearing requirements. At the same time, the anti-corrosion performance of the racking is inspected, focusing on checking whether the galvanized layer is damaged or rusted at the welding parts and bolt connections. Finally, the safety accessories such as safety warning signs, anti-collision guards, and column protectors are installed to further enhance the safety of the racking system. After all inspections are qualified, we jointly conduct a handover acceptance with the client’s technical and management personnel, and explain to the client the daily operation specifications, maintenance points, and safety precautions of the racking system, ensuring that the client can use and maintain the system correctly. Installation Results & Project Benefits Installation Results After 25 days of intense and orderly construction, the drive-in racking system was successfully installed and debugged, and passed the joint acceptance of both parties. The system operates stably in the low-temperature environment of -18°C, with all technical indicators meeting the design requirements and national industry standards. The actual storage capacity reaches 11,520 pallet positions, 3.6 times that of the original warehouse, fully meeting the client’s demand for high-density storage. The racking has a neat and beautiful appearance, with no obvious deformation or rust after 6 months of operation, and the anti-corrosion and stability performance are excellent. Core Benefits for the Client Space Utilization & Storage Capacity: The drive-in racking cancels the traditional forklift access aisle, and the storage lanes are closely arranged, increasing the warehouse space utilization from less than 40% to more than 85%, and the storage capacity is increased by 260%. The client does not need to expand the warehouse area, saving more than 8 million yuan in real estate investment and construction costs. Operational Efficiency & Inventory Management: The system realizes batch storage of homogeneous goods, and the forklift can directly drive into the storage lane for loading and unloading, which reduces the time of inventory access by more than 50% and significantly improves the efficiency of warehouse operations. The "first-in, last-out" sto

Shuttle Rack Installation Case – UK Food Company 1. Project Background BritFoods Ltd is a well-known prepared food and ready meal manufacturer in central UK, mainly engaged in baking, cooked food and frozen processed food, supplying major British supermarkets and chain catering brands. The original warehouse adopted conventional pallet racking with manual forklift operation, bringing three major pain points: Insufficient storage capacity: Annual order growth reaches 18%, causing warehouse overstock in peak seasons and high costs of renting additional cold storage. Low operational efficiency: A large number of food SKUs and strict batch management make manual picking and layer transfer time-consuming. It is difficult to implement FIFO, resulting in high near-expiry waste. High labor cost: Labor cost is extremely expensive in the UK. Night shift forklift operators are hard to recruit; working in low-temperature warehouses also brings high labor intensity and potential safety risks. Warehouse Basic Information Location: Birmingham, UK Building: Single-story steel structure constant temperature & low-temperature warehouse (0℃ ~ -22℃ zoning) Available Area: About 1350㎡ Clear Height: 9.2m Pallet Spec: European standard EUR pallet 1200×800mm, load capacity 1000kg 2. Core Customer Requirements High-density storage: Double the storage capacity within the existing site without new construction. Strict FIFO mode: Realize batch management and shelf-life traceability to meet UK FSA food standards. Low-temperature adaptation: The whole system can operate stably at -22℃ with condensation prevention and low-temperature resistant batteries. Semi-automation & easy operation: Cooperated operation of forklifts and shuttle cars to maintain flexibility and reduce over 30% on-site labor. ERP connection: WMS/WCS system dock with customer existing SAP for real-time inventory synchronization. 3. Solution – Four-Way Shuttle Car Intensive Warehouse System 1. Core Configuration Rack Type: Four-way shuttle car intensive racking (FIFO channel design) Storage Locations: More than 2700 pallet positions, increased by 317% compared with original 850 positions of conventional racking Channel Depth: 12~15 pallets depth per lane, 6 layers, total height 8.8m Shuttle Cars: 8 sets low-temperature resistant four-way shuttle cars, adaptable to -25℃ environment Lifts: 2 sets vertical layer-changing lifts for automatic cross-layer scheduling Forklifts: 3 sets electric counterbalance forklifts for loading & unloading connection Software: WMS warehouse management system + WCS equipment scheduling system, interfaced with SAP 2. Layout Design The warehouse is divided into inbound connection area, shuttle car intensive storage area, outbound sorting area and low-temperature buffer area. Adopt double-end FIFO design: inbound at one end and outbound at the other, realizing one-way flow of goods to avoid batch mixing. Fire passage and maintenance passage are reserved in compliance with UK building regulations and BS EN fire safety standards. 3. Working Process (FIFO) Inbound: Forklifts place full pallets at the inbound platform → shuttle car automatically receives goods and drives into designated lane and layer → automatic storage and positioning. Storage: WMS automatically records batch number, shelf life and location, sorting strictly by production date. Outbound: The system dispatches shuttle cars automatically according to FIFO rule → deliver the earliest batch pallets to outbound end → forklifts pick up goods for delivery. Inventory Checking: Automatic system inventory + shuttle car code scanning recheck, inventory accuracy ≥ 99.5%. 4. On-Site Installation & Implementation Phase 1: Foundation and Embedded Parts (2 Weeks) Concrete strength reaches C30 standard with floor flatness error ≤3mm/m. Anchor bolts are pre-embedded; antifrost expansion treatment is applied in low-temperature area to prevent floor cracking under low temperature. Phase 2: Main Frame & Beam Installation (4 Weeks) Adopt European standard heavy-duty rack profiles with epoxy powder spraying, featuring rust and corrosion resistance, adapting to humid climate in the UK. Install main uprights → cross bracings → layer load beams → adjust horizontal & vertical level with error ≤2mm. Complete fastening and self-inspection block by block, fully complying with CE safety standards. Phase 3: Rail & Shuttle Car Installation (2 Weeks) High-precision rail installation with straightness ≤1mm/10m and seamless joint to ensure stable driving of shuttle cars. Commissioning items: 72-hour continuous operation test at -22℃; four-way traveling and rail changing positioning accuracy within ±5mm; linkage debugging with lifts for cross-layer scheduling. Phase 4: WMS/WCS System Deployment (2 Weeks) Local server deployment to meet UK data compliance requirements. Develop interface to connect with SAP for order and inventory synchronization. Complete full-process simulation and peak pressure test. Phase 5: Training & Acceptance (1 Week) Provide professional training on daily operation, fault handling and routine maintenance. Deliver English operation manual, maintenance manual, electrical schematic diagram and CE certification documents. Joint acceptance by both parties with 72-hour trouble-free continuous operation, all indicators up to standard. 5. Project Benefits Storage Capacity: Under the same area, pallet positions rise from 850 to over 2700, increased by 317%, no need to build new warehouse. Efficiency & Labor: Inbound & outbound efficiency reaches 180~200 pallets per hour, 3 times higher than manual operation; on-site staff reduced by 42%, greatly cutting high night shift labor cost. Food Compliance & Loss Control: Strict FIFO mode reduces near-expiry loss by 60%, fully meeting UK FSA food traceability requirements; inventory accuracy over 99.5%. Cost Return: Annual comprehensive cost saving up to £250,000, investment payback period about 2.8 years. 6. Customer Testimonial "The shuttle rack system perfectly solves our warehouse overstock and efficiency bottlenecks. With high labor costs and strict compliance regulations in the UK, this solution allows us to cope with market growth in the next 3-5 years without new land investment. The FIFO and traceability system fully meets the strict audit requirements of British supermarket clie

With over a decade of industry experience as a direct manufacturer, our cantilever racking stands out with superior quality and competitive pricing. All products are fully customizable, allowing flexible adjustments to design based on your warehouse space, cargo type, and operational needs.  From material selection to structural optimization, we oversee every production step to ensure each rack is durable and tailored to real-world usage, delivering an efficient and reliable solution for your storage system. Whether storing pipes, profiles, or plates, we can maximize space utilization and enhance storage efficiency through customized design. Key Advantages of Cantilever Racking 1.High Space Utilization:Open cantilever design accommodates long, wide, or irregular items (e.g., pipes, timber, plates), eliminating space waste from traditional racks. 2.Easy Access:No crossbeams block access—forklifts or cranes can load/unload directly from the side, boosting operational efficiency by over 30%. 3.Sturdy Structure:Welded with high-strength steel, the cantilever-column connection is robust. Customized load-bearing design ensures safe storage of heavy goods. 4.Flexible Adaptation:Adjust cantilever spacing based on cargo height, or add accessories like guardrails and label holders to meet diverse storage needs.