Warehouse Racking Systems

Warehouse Design and Planning

Strategic warehouse planning will lay the foundations of an effective warehouse operation; however the process involves smart deliberate decisions based on specialist knowledge and for most, such expertise are not an in-house resource. This is why WSL provide free planning consultancy as part of our service.

On a daily basis WSL design warehouse solutions for projects of all sizes and at every level of complexity using the extensive knowledge and expertise of our Technical Design team.

Why Planning Matters

As its foundation, the way in which your warehouse space is utilised will determine the success of the business, because a successful business relies on organisation. Attentive planning considers all aspects of your operation to ensure your final solution is designed to provide maximum support.

Whether you are looking to improve your current operation or open a new facility, our Technical Designers will plan your warehouse space purposefully to underpin an operation which will facilitate heightened productivity and efficiency levels.

Designing a warehouse plan

The Principles of an effective warehouse plan

In broader terms an effective warehouse plan will maximise your space, support your inventory and save time yet in order to achieve this, specific individual factors need be considered. These include:


Budgeting is the first and most critical stage of the project because it provides an understanding the financial involvement and helps determine project fund allocation. If you’re new to project budgeting it may be less intimidating if you focus on one element at a time as you gather cost estimates for your requirements, as you work towards a finalised budget.

Armed with your project criteria and budget, our committed design team will plunge into a design that not only meets your expectations but your budget too. Our team’s commitment to ‘design to budget’ together with our unique position as a stockist and accredited manufacturer means we have the ability to contain various costing, without compromising the expected outcome.


One of the main issues concerning space is congestion which can slow down an operation to the point where productivity levels are at great risk of falling. There are numerous ways in which to gain maximum use of your space through the design of your structures and systems. Techniques such as narrowing down the aisle width of the racking areas, implementing deep storage systems or storing at height will promote optimal use of space and stimulate efficiency.  

As a combined team, our designers have spent over 100 years designing space optimising solutions and during those years they have acquired a wealth of knowledge and experience. Before pen goes to paper, one of our designers will assess your space in person as they carry out a free site survey. Consider this as a ‘fact-finding mission’ where all aspects of your space is painstakingly analyzed by the Design Technician who can then use those findings to make the most informed decisions during the development of the design.  The solutions for your particular operation will depend on your individual business needs and available space, although the most optimal and cost-effective solutions will be guaranteed when designed by a WSL Technical Designer.


Our designers will be particular keen to learn about the characteristics of your inventory including unit dimensions, weight, volume and turnover as well as any particular obligations such as the need for temperature controlled environments or stock rotation.  Once the right type of storage system has been determined, it will be incorporated into a bespoke configuration by our designer who will ensure the solution will meet both inventory and operational needs whilst utilising space.

Warehouse inventory calulations
Warehouse racking and layour plan example


A key promoter of effective workflow is an optimal warehouse layout because it provokes logically sequenced activities. If departments and functions are strategically positioned, people and goods can journey from stage to stage seamlessly and without the interruption of unnecessary travel or change of direction. 

The goal of our designer will be to determine the most optimal layout for your warehouse in order to simplify directional movement and incorporate an effective travel pattern into the warehouse layout plan. The most considered patterns would be I, L or U shaped and yours would be determined by the location of your goods-in and goods-out as illustrated in the diagrams:

Inventory directional flow diagrams


Your access requirements are a highly influential factor when it comes to the design of your warehouse solutions because it governs the arrangement of pallets or units whilst in storage. With selective racking for example, all pallets are immediately visible and accessible. This is ideal where pallets per SKU is low, however high SKUs would be better suited to a deep storage solution, particularly if space is limited. This would mean that only the pallets rested on the picking face are immediately visible and accessible making it responsive to a systemised picking process rather than random order picking.


Raising the bar on safety and performance, supplementary equipment and fixtures are an integral part of your warehouse operation. Like all other aspects your warehouse design, any such ancillaries will be arranged in accordance to your operational needs and can include anything from safety barriers, walkways and weight load notices to fork lift trucks, pallet gates and conveyors.

The Moonpig Warehouse Design

Moonpig shelving system

Taking Market Leadership

As an online retailer, Moonpig.com embraced new opportunities born from advancements in technology and global circumstances to expand and retain its customer base. Owing to continual technological investments and an expanding product range, the online card and gift retailer continues to embrace roaring success despite the demise of the pandemic-induced surge.

Having gained significant market leadership over the last two years, the next step for Moonpig was to enhance their logistical operation by bringing it in-house.

The Moonpig Warehouse

The retailer went on to acquire a new 92,000sqm warehouse building, located in Tamworth and conveniently close to a Royal Mail Hub and this has since been transformed into a fully operational and successful fulfilment centre.

The facility boasts of optimal solutions implemented by WSL following a design created by one of our most experienced Design Technicians. Having outshone the designs created by other providers, the WSL design offered the most optimal solution and was engaged with every aspect of the operation. As a stockist with in-house manufacturing capabilities, enhanced flexibility and limited constraints meant a solution that would meet the exact needs of the operation. As one multifuncional team of many skills and talents, WSL was able to deliver the whole package for Moonpig.

Moonpig Work benches
Moonpig Pallet Racking

The Moonpig Warehouse Solution

The warehouse design consisted of multiple solutions and these included:

5760 no. very narrow aisle (VNA) racking locations

A 1672m2 Mezzanine Floor complete with two staircases, three pallet gates and a goods lift

232 no. temperature controlled pallet racking locations

2000 no. pick bin shelving locations

105 no. work benches

12 no. fork lift trucks including VNA, reach and counterbalance trucks

As a UKCA accredited manufacturer, certain products were manufactured in-house. These included the mezzanine floor, staircases, pallet gates and work benches. We also designed and manufactured pick and deposit stations (P&Ds) which were fitted to the end of the VNA racks. These are used to increase efficiency by allowing the VNA trucks to remain operational between the racks whilst working with the counterbalance trucks which operate beyond the racks.

The benefits

Why Choose WSL to Design your Optimal Warehouse Plan?


Extensive Knowledge and Experience

With this comes expansive understanding and the ability to create of outside the box solutions to meet your exact needs


The Promise of Cost-Effectiveness

Our designers strive to produce highly effective solutions that will minimise operational running costs and see a return on your investment


In-House Manufacturing

This eliminates supply chain issues constraining the design whilst increasing flexibility and cost-effectiveness


Our "Design to Budget" Committment

Assuring you of the most optimal solution without inflicting budgetary implications.


High Accreditations you Can Trust

These includes our Full SEMA membership (Storage Equipment Manufacturers Association) and UKCA certification which reflect our commitment to ensuring the very highest standards of quality and safety.

Why choose wsl?

What Sets Us Apart

Our dedicated and experienced team will take time to understand your goals and asses your needs. Our extensive market knowledge and practical experience enables us to design and develop a bespoke system that is as unique as your business. Here at WSL we aim to maximise your available space and increase productivity through creating innovative and ‘outside the box’ solutions. Our commitment to excellence, our portfolio and our recommendations provide our customers with confidence in our ability to deliver solutions that are not only superior, but very cost-effective. Our in-house services simplify the process from design to installation by giving you just one port of call. By continuing to remain independent across the whole market we commit to providing our valued customers with the highest quality and – wherever possible – British products, all at competitive prices. We aim to fit our pallet rack systems with as little inconvenience to our clients as possible, using highly experienced fitters overseen by qualified project managers.

Our Accreditations

client stories

Some Case Studies

Our warehouse Racking experience is extensive. Take a look at a very small selection of some of the pallet racking projects we have completed over the years.

Trusted by all

Just Some Of Our Clients

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Discuss Your Project

Our service is completely client-centric. We provide all manufacturer types, as well as fitters, engineers and inspectors; which means that not only can we deliver your entire project from start to finish, but that we can provide a fully bespoke solution for your individual needs. Get in touch to find out more.