With such a wide variety of both existing and potential customers, 3PLUK required a storage solution that would optimise storage density and order velocity, particularly for such a wide range of products that can vary in size and shape.

Avanta UK proposed a multi-tier pick structure to utilise the available height, to be constructed from pallet racking, as well as incorporating a mezzanine floor for loading and marshalling areas. The racking structure with adjustable beams enables customisation if the product profile changes, such as in the event of a new contract win for the client. Levels can be converted from narrow shelving to storage for pallets if required.

The Multi-tier structure, has a footprint of 48.7m length x 28.9m wide with ground and 2 walkway levels at 2,435 and 4,835mm. This gives the client circa 4200m2 of storage space. Ground and level 1 was to store boxes and a variety of pick totes. The top level had extended racks with garment rails to store specific longer garments for a particular client.

The design included a flat chipboard surface to all walkway levels using Class O foil backed boards enabled the smooth operation of pump trucks and mobile pick steps / trolleys.

The structure incorporated a multi-level mezzanine floor with access via 4x staircases for personnel and 2x pallet gates for loads. Safety perimeter handrail and mesh fitted to prevent the fall of small items was supplied and installed by Avanta.

As part of this project, Avanta designed, supplied and installed a run of additonal pallet racking outside of the structure for bulk storage with upright guards and anti-collapse mesh.

The new storage and fulfillment facilty has enabled 3PL to attract multiple new clients with specific areas with the structure dedicated to each client with different storage requirements.

What is a Pick Tower / Pallet Racking with Walkways & Incorporating a Mezzanine Floor?

A Pick Tower is a free-standing structure, that it is designed to provide storage to all levels of the structure, within the same footprint. This storage system is also known as a rack supported structure and is used to improve picking efficiency and maximising storage capacity. This is achieved by utilising the available height in the warehouse.

The structure utilises double or multiple height shelving or pallet racking with steel angels to support the flooring materials (Could be chipboard, steel etc) to create walkways and steel staircases to provide access to all products. A self-supporting structure with 100% accessibility.

Benefits of a Multi-tier Shelving

The system is cost effective as it reduces the requirement for large structural steels as the strength is from the shelving / racking structure. Also, you can maximise the storage height and headroom within the structure as there is not the requirement for large beam supports – a thin line structure.

These systems are a cost-effective alternative to mezzanine floors or extending the warehouse facility or relocation with a reduced imposed load on the slab due to the number of uprights incorporated.

Can I Incorporate a Mezzanine Floor?

Often, multi-tier systems or pick towers incorporate a mezzanine floor at one end or both ends. This additional area may be used for a pick and pack area that could incorporate picking benches, conveyors and trolleys. The mezzanine element maybe used to deposit pallets via goods lift or handling equipment on to multiple levels for the bulk stock to be separated out on to the shelving. Mezzanines attached to pick towers offer the client extra space for a marshalling area and / or have cut outs for parcel chutes.