Pallet Racking & Boltless Shelving Installation for Unilever’s R&D Facility
When Unilever’s Research & Development team at their Sharnbrook site started reviewing how their space was being used, one thing became clear. The way stock was stored no longer matched how the site was operating day to day. As the volume and variety of equipment, materials and consumables grew, so did the pressure on the existing layout.
They needed more than just extra storage. The objective was to improve flow, increase capacity and make sure the space could support how the site would work in the future, not just now.
That’s where BSE UK came in.
Here, we take a look back at the details of the project.
Understanding the warehouse storage challenge
Unilever approached BSE UK looking for a practical, scalable warehouse storage solution that would support several different areas across the site. Adam Griffiths from the Unilever team explained that they needed a mix of pallet racking and boltless shelving, alongside the relocation of some existing racking to improve overall layout and efficiency.
The key challenge was space. The footprint of the building was fixed, but the demands on it were increasing. Different departments had different storage needs, from palletised goods in the dry store, through to boxed items, archives, cleaning supplies and engineering equipment.
It wasn’t just about fitting more in. It was about creating a system that made sense operationally. Clear access routes, safe working practices and flexibility for future changes were all part of the brief.
Designing the right pallet racking system
Simon Lock from BSE UK led the design of the new pallet racking installation, starting with the dry store. This area needed to handle both Euro pallets (800mm x 1200mm) and standard pallets (1000mm x 1200mm), while making the most of a compact space.
Rather than defaulting to wide aisles, Simon designed a layout with slightly narrower aisles to maximise pallet capacity without compromising safety or usability. This allowed Unilever to achieve the pallet numbers they required within the available footprint.
The system was built with multiple levels and durable wire mesh decking. This gave Unilever the flexibility to store non-palletised items on upper levels, which was particularly useful for mixed stock and irregular items.
Each bay was designed to handle up to 12,000kg, with 3,000kg per level, providing the strength and reliability needed for a busy R&D environment.
Because of the tighter aisle widths, Simon specified the use of Bendi or Flexi articulated trucks. These trucks have a much smaller turning circle than traditional forklifts, making them ideal for narrow aisle pallet racking. This choice ensured the system would not only fit physically, but also work smoothly in practice.
Reconfiguring their existing storage layout
Alongside the new pallet racking installation, Unilever also wanted to make better use of their existing assets. Part of the project involved dismantling an existing pallet racking system and reinstalling it in their Reserve Equipment Store.
The brief here was simple: reuse what was already available, with only new floor fixings and a small number of additional bays added where needed. This approach kept costs under control while still delivering a meaningful improvement in how the space was organised.
By relocating and reconfiguring the racking, Unilever were able to create a more logical flow between areas, reduce congestion and free up valuable space in key operational zones.
Boltless shelving for multiple departments
Beyond pallet storage, several departments required a different type of solution. Heavy duty boltless shelving systems were installed across the Cleaning Store, Archive Stores, Furniture & Equipment Store and Apleona Engineering Stores.
These areas needed easy access, clear visibility and shelving that could adapt as requirements changed. Boltless shelving was the ideal fit.
The systems were fitted with chipboard shelves in widths ranging from 1830mm to 2135mm, tailored to suit each space and the items being stored. Finished in painted grey beams with blue frames, the shelving provides a clean, consistent look across the site.
Each level is capable of holding up to 500kg, which was more than sufficient for Unilever’s needs, while still allowing teams to reconfigure shelf heights as stock profiles evolve.
Racking installation and delivery
The full project was delivered by the SEIRS installation team, working closely with BSE UK and Unilever to ensure minimal disruption to daily operations. SEIRS operates under SEMA to ensure that storage equipment installers meet industry standards for competence and safety.
Specialist equipment, including scissor lifts and forklift trucks, was used throughout the installation process to ensure everything was completed safely and efficiently.
From initial design through to final handover, the focus remained on creating a storage system that felt like part of the building, not an add-on. Every area was designed around how people actually use the space.
A solution built around real needs
What makes this project stand out is not the scale, but the thinking behind it. This wasn’t about installing as much racking as possible. It was about understanding how the site operates, where the pressure points were, and what Unilever needed from the space over the long term.
The result is a warehouse storage solution that supports:
- Higher pallet capacity within the same footprint
- Safer, more efficient movement through the use of articulated trucks
- Flexible storage for mixed stock and changing requirements
- Better organisation across multiple departments
- A layout that can adapt as the site continues to grow
It’s a good example of how warehouse fit out projects work best when they start with real operational objectives, not just product specifications.
Simon Lock on the project
Simon Lock, who led the design of the solution, reflected on the project:
“Pallet racking and boltless shelving are the core of what BSE UK have been doing for more than 50 years. Projects like this are always a pleasure to work on, to discuss the requirements of the customer and then design a solution that fully suited to what they need. It’s rewarding to see how it benefits them. Great to work with Alex on this. Thank you.”
BSE UK: Creating smarter spaces for growing businesses
For BSE UK, this project with Unilever is a clear example of what modern warehouse storage should look like. Rather than a racking-first approach, a carefully planned environment that supports how people work, how stock moves and how the business is likely to evolve.
Whether it’s pallet racking installation, boltless shelving or full warehouse reconfiguration, the real value comes from understanding the customer first. Their challenges, their constraints and their goals.
In Unilever’s case, the outcome is a smarter, more efficient R&D facility that can handle current demand and stay flexible for whatever comes next. And that’s exactly what good storage design should achieve.
If you’ve got an upcoming storage project and want to talk through your options, you can call the BSE UK team on 0117 955 5211, email [email protected], or book a free site survey to see what’s possible in your space.
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