Transforming a Global E-commerce Fulfillment Center with ASRS Rack
Client: Velocity Commerce (a pseudonym for a leading global e-commerce retailer)Industry: E-commerce & LogisticsChallenge: To address explosive sales growth, severe labor shortages, escalating land costs, and the need for next-day delivery promise in a major metropolitan hub.Solution: Design and implementation of a high-density, fully automated ASRS (Automated Storage and Retrieval System) rack-supported warehouse.Results: 300% increase in storage capacity, 500% improvement in peak order processing speed, 99.995% inventory accuracy, and 60% reduction in operational labor costs within the same building footprint.
1. Executive Summary
Facing unsustainable operational pressures, Velocity Commerce embarked on a transformational automation project at its flagship regional fulfillment center. By deploying a state-of-the-art ASRS rack system as the core of its new logistics infrastructure, the company not only solved its immediate capacity and labor crises but also established a scalable, precise, and highly efficient hub capable of supporting its growth for the next decade. This case study outlines the journey, the technology, and the profound business impact.
2. The Challenge: Growth Pains at Scale
Velocity Commerce’s existing manual warehouse, spanning 150,000 sq. ft., had hit critical limitations:
Space Exhaustion: Storage was completely full. Expanding the building footprint in the high-cost urban location was financially prohibitive.
Labor Intensity & Instability: The facility relied on over 200 forklift operators and pickers. High turnover, training burdens, and seasonal hiring spikes led to inconsistent productivity and rising costs.
Throughput Ceiling: During sales events like Black Friday, the manual system maxed out at 25,000 order lines per day, causing dangerous delays and missed delivery guarantees.
Accuracy & Traceability Issues: A 98.5% pick accuracy rate resulted in significant costly returns, mis-ships, and inventory discrepancies, damaging customer trust.
The business needed a paradigm shift—not just more space or people, but a fundamentally smarter way to store and handle goods.
3. The Solution: An ASRS Rack Ecosystem
Working with a premier systems integrator, Velocity Commerce implemented a tailored ASRS rack solution. The system was not merely racks but an integrated ecosystem:
A. Physical Infrastructure: The High-Density ASRS Rack Framework
Structure: 32-meter-high (105 ft) steel racking, utilizing the full clear height of the building. The design featured narrow aisles (only ~1.5m wide) for stacker cranes, creating ultra-dense storage for over 50,000 pallets and trays.
Configuration: A hybrid system with two zones:
Pallet ASRS: For full-case storage of fast-moving items, with deep-lane configuration for high-volume SKUs.
Mini-Load ASRS: For slower-moving and smaller items stored in standardized totes, enabling automated "goods-to-person" order picking.
Integration: The rack structure seamlessly interfaced with inbound/outbound conveyor networks, automated palletizers, and a fleet of AMRs (Autonomous Mobile Robots) for case movement to packing stations.
B. The "Nervous System": Automation & Software
Hardware: 12 high-speed stacker cranes (for pallets) and 8 mini-load retrievers operated 24/7 in the aisles. They are guided by ultra-precise laser positioning systems.
Control Brain: A robust Warehouse Control System (WCS) directly controls all automated equipment in real-time, optimizing travel paths and task sequences.
Management Intelligence: The WCS is seamlessly integrated with the company’s Warehouse Management System (WMS), which manages all inventory data, order prioritization, and business rules. Every single tote and pallet location is tracked in real-time.
4. Implementation & Go-Live
The project followed a phased approach over 14 months:
Detailed Simulation: The entire system’s performance was modeled and stress-tested digitally before construction began.
Parallel Build & Operation: A section of the old warehouse remained operational while the ASRS was constructed in stages, minimizing business disruption.
Staged Commissioning: System testing began with individual components, then aisles, and finally full integration with the WMS/WCS.
Training & Transition: A core team of technicians and operators was trained extensively, transitioning staff from manual laborers to system supervisors and problem-solvers.
5. The Results: Quantifiable Transformation
The impact of the ASRS rack system was dramatic and measurable:
Metric
Before (Manual)
After (ASRS)
Improvement
Storage Capacity
150,000 sq. ft. at capacity
Effective capacity of ~450,000 sq. ft. within same footprint
300% Increase
Peak Order Processing
25,000 order lines/day
125,000+ order lines/day
500% Increase
Inventory Accuracy
~98.5%
99.995%
Near-Perfect Accuracy
Labor for Storage/Picking
200+ employees
~80 system supervisors & technicians
60% Reduction
Order Cycle Time
4-8 hours (pick to ship)
Consistent under 1 hour
75%+ Faster
Energy Consumption
High (diesel forklifts, lighting)
Lower (electric stackers, zone lighting)
35% Reduction
Safety Incidents
Moderate (forklift-related)
Near Zero (man-machine separation)
Dramatic Improvement
Additional Strategic Benefits:
Scalability: The rack structure and control system are designed for easy future expansion by adding more aisles vertically or laterally.
Uninterrupted Operations: The system operates reliably in three shifts, unaffected by shift changes, breaks, or labor shortages.
Enhanced Data Capital: The real-time, granular inventory data enables better demand forecasting, purchasing, and supply chain planning.
6. Conclusion & Strategic Outlook
For Velocity Commerce, investing in an ASRS rack system was not an expense but a strategic capital investment in its operational DNA. The system successfully turned its greatest constraints—space, labor, and accuracy—into core competitive advantages.
The warehouse is no longer a cost center but a high-performance, predictable, and reliable engine for customer satisfaction. This case demonstrates that for large-scale, high-velocity operations in competitive markets, ASRS rack technology provides the definitive answer to achieving and sustaining market leadership. Velocity Commerce is now poised to replicate this model in other global hubs, using data from this flagship center to refine and optimize future deployments.
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Wire Mesh Decking: Enhancing Warehouse Safety and Storage Efficiency
In today’s fast-paced logistics and warehousing environment, safety and efficiency are critical to daily operations. One common but often underestimated risk is pallet failure. When pallets break or shift unexpectedly, falling goods can cause serious damage to inventory, equipment, and—most importantly—personnel.
Wire mesh decking offers a simple yet highly effective solution for modern pallet racking systems. Installed directly on pallet rack beams without the need for tools, wire mesh decking provides an added safety layer that helps prevent goods from falling when pallets fail or are improperly positioned.
Designed for industrial use, wire mesh decking can support load capacities ranging from 200 kg to 1,000 kg, depending on mesh structure and wire diameter. Beyond load support, it significantly improves fire safety compliance, allowing sprinkler water to pass through more effectively. The open-mesh design also enhances airflow and lighting, creating a safer and more organized warehouse environment.
At Nanjing Peter Logistics Equipment Co., Ltd., we manufacture and customize wire mesh decking to match different rack dimensions, pallet sizes, and load requirements. Our solutions are widely applied in combination with heavy-duty pallet racking and industrial cantilever rack systems, making them suitable for logistics centers, manufacturing plants, and distribution warehouses.
By upgrading pallet racking systems with wire mesh decking, businesses can reduce risk, improve compliance, and extend the service life of their storage systems—without increasing installation complexity.
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Press Release: Double Deep Racking System Launched, Boosting Warehouse Density and Efficiency
Faced with the dual challenges of limited warehouse space and rising operational costs, how can businesses significantly increase storage capacity without expanding their premises? Nanjing Peter Logistics Equipment Co., Ltd. has launched an efficient Double Deep Racking System, designed to help enterprises dramatically improve warehouse space utilization through optimized storage structure.
The system adopts a back-to-back, double-row pallet design, allowing forklifts to store and retrieve two rows of pallets from a single aisle, greatly reducing aisle space. Compared to conventional racking, the double deep system can increase storage capacity by 30–40%, lowering the cost per pallet stored and providing a cost-effective solution for businesses with high inventory volumes.
Key advantages of this racking system include:
High-Density Storage: Significantly improves warehouse space utilization, especially suitable for cold storage, food & beverage, and manufacturing industries.
Robust Structure: Features reinforced uprights and beams with bracing, ensuring stability under heavy loads.
High Load Capacity: Each pallet position supports 1,000–3,000 kg, meeting most heavy-duty storage requirements.
Process Compatibility: Ideal for businesses with fewer SKUs, bulk handling, and full-pallet in/out operations, and works efficiently with equipment such as reach trucks.
With 15 years of expertise in the design and installation of warehouse storage systems, Nanjing Peter Logistics Equipment Co., Ltd. serves clients worldwide, offering customized solutions based on actual site conditions and operational workflows to help businesses achieve smarter, more intensive warehouse management.
"In today's environment of high land and operating costs, optimizing storage space has become key to reducing costs and improving efficiency for businesses," stated a company project lead. "Double deep racking not only increases storage volume but also enhances logistics efficiency through scientific layout, making it an excellent choice for modern warehouse upgrading."
Companies interested in learning more about the system's applicability and implementation solutions can find further details via the link below:
https://pallet-storagerack.com/sale-54479657-single-side-industrial-heavy-duty-metal-cantilever-rack-industrial-arm-racking-system-heavy-duty-sta.html
Maximize Your Storage Potential: The Superior Advantages of Our Professional Warehouse Racking Systems
Is your storage space a maze of inefficiency? Are you struggling with chaotic inventory, low accessibility, and wasted vertical space? The solution lies in a systematic, high-density, and robust storage foundation.
At [Your Company Name], we engineer warehouse racking systems that transform your storage operations from a cost center into a strategic asset. Here’s how our solutions deliver unmatched advantages:
1. Unparalleled Systematic Organization & ScalabilityA warehouse is an ecosystem. Our systems, designed with a logical structure like the A1 to A1000 indexing in your layout, bring absolute order. Every pallet, every box has a dedicated, identifiable home. This modular design allows for seamless scaling—start with a hundred positions and expand to thousands without redesigning your entire flow. Perfect for growing businesses and dynamic inventory needs.
2. Maximum Space Utilization with High-Density StorageFloor space is expensive; we help you capitalize on the often-neglected air space. Our pallet racking, drive-in/drive-through systems, and cantilever racks are engineered for high-density storage. By safely stacking loads vertically and configuring aisles optimally, we dramatically increase your storage capacity within the same footprint, delaying or eliminating the need for costly facility expansion.
3. Optimized Accessibility & Operational EfficiencySpeed is money. Our racking configurations, including selective pallet racks, ensure direct access to every single load (SKU). This First-In, First-Out (FIFO) or Last-In, First-Out (LIFO) compatibility minimizes picking time, reduces labor costs, and accelerates order fulfillment. An organized system means your forklifts and workers spend less time searching and more time doing.
4. Engineered for Strength, Safety, and Long-Term ValueWe don’t compromise on safety. Our racks are manufactured from high-strength, hot-dip galvanized steel, providing exceptional resistance to corrosion, wear, and impact. Every beam, upright, and connector is precision-engineered and rigorously tested to exceed industry standards (like RMI/ANSI MH16.1), ensuring safe support for your heaviest loads for decades. This durability translates into a lower total cost of ownership and unwavering operational safety.
5. Custom-Designed for Your Specific NeedsYour operation is unique. We offer more than just standard sizes. Our team works with you to analyze your inventory profile (size, weight, turnover rate), equipment, and workflow. The result is a tailored racking solution that fits your space perfectly and supports your specific business processes, maximizing ROI from day one.
6. Built for Modern IntegrationOur racking systems are the perfect physical backbone for modern Warehouse Management Systems (WMS). The clear, systematic addressing (e.g., Aisle A, Position 055) integrates seamlessly with barcode/RFID technology, enabling real-time inventory tracking, automated picking lists, and flawless accuracy.
Invest in a Foundation for Growth.A superior warehouse isn't just about storing goods; it's about enabling faster throughput, greater accuracy, and scalable growth. Our racking systems provide the reliable, efficient, and safe foundation your logistics operation needs to compete and win.
Ready to transform your storage chaos into a model of efficiency?Contact [Your Company Name] today for a free consultation and custom storage analysis.
https://mao.ecer.com/test/pallet-storagerack.com/sale-54478667-industrial-heavy-duty-pallet-racks-shelves-system-stacking-units-metal-rack-warehouse-steel-pallet-r.html
