Warehouse growth is rarely a straight line. Seasonal stock levels bring throughput and workflow pressure that peaks and dips through the year, product ranges can expand faster than the floor plan was built for, and systems that worked before start to strain within a couple of years. Getting warehouse shelving right from the start leads to less reconfigurations later, and a layout that can manage growth as the business does, without just coping.

For operations handling small to medium inventory (cartons, parts, multi-SKU ranges, e-commerce orders), shelves in warehouse settings can often do more of the daily work than pallet racking does.

This guide looks at where shelving is best suited, the main types worth considering, and how to choose a setup that matches your picking patterns rather than following a standard template.

Shelving & pallet racking: When to use each

Racking and shelving solve different problems, and mixing them up early tends to cost money later.

Pallet racking is built for bulk picked using forklifts. It suits palletised loads, forklift access, and stock that moves in whole units rather than individual items. Warehouse shelves, on the other hand, are designed around a person doing the picking. Likely in smaller units, with fast turnover, and items that get touched by hand rather than a machine.

A useful way to think about it is if a forklift is involved, you’re in racking territory. If a person is walking the aisle with a pick list, shelving is the solution. Many sites need both types of storage systems – usually bulk storage systems feeding shelving units arranged for hand pick operations, with storage bays organised around how staff move through the warehouse.

Common shelving types for small & medium inventory

Different stock profiles call for different shelving units. Here’s where each storage system is best suited.

Longspan shelving

Longspan shelving suits bulkier or irregularly shaped items that don’t sit well on standard shelf depths – for example, spare parts, packaging materials, or stock that varies in size batch to batch. The wider bays and adjustable beam heights make it a strong fit for stock that doesn’t come in neat, uniform boxes. Longspan doesn’t require a shelf at floor level, meaning palletised goods can be stored on the ground, with hand pick operations on the shelves above – a set up commonly used in wholesale environments and builders merchants.

Boltless shelving

Quick to assemble and just as quick to reconfigure, boltless shelving is a practical and cost efficient choice for growing operations that expect their layout to change. No fixings, no tools, shelf heights that adjust as stock profiles shift and a wide range of sizes, shelf materials and load capacities up to 800kg depending on specifications.

Adjustable shelving

Where boltless shelving prioritises speed, adjustable steel shelving is the choice for long-term flexibility. Shelf levels can move as products come and go, without needing to redesign the bay from scratch.

Mobile & compact shelving

For sites where floor space is the real constraint, mobile shelving compresses aisle space by moving units on tracks, only opening the aisle you need. It’s a strong option where inventory density matters more than pick speed. This solution is commonly used in archive sites and retail stockrooms where space is limited but stock requirements are high.

Industrial steel shelving

Industrial steel shelving is the workhorse option – built for medium duty shelving and heavy duty shelving loads, and rated up to extra heavy duty shelving specifications where stock is dense or awkward. It’s the type most operations default to, and for good reason: durability without unnecessary bulk.

Chrome wire shelving

Lighter duty, easy to keep clean, chrome wire shelving works well in smaller stockrooms, retail storage, clean environments or anywhere ventilation and visibility matter most.

Multi-tier shelving

For sites with building height to spare but limited floor space, multi-tier shelving extends shelving height vertically, split by a first floor level, stairs and walkways. It’s a strong way to multiply storage without extending the building footprint.

Benefits of warehouse shelving

Well configured shelves in warehouse spaces do much more than hold stock, they shape how efficiently a whole warehouse shift can run, providing the layout, shelf labelling and shelf type are best suited for the operation.

Improved accessibility & efficiency

Shelving layout and stock placement puts fast moving product lines within easy reach and slower stock further out, cutting the distance staff walk on every pick. Small changes in layout logic can have a big impact across a full shift, and over time that creates a meaningful uplift in warehouse efficiency.

Cost-effective

Compared with automated storage systems or large scale pallet racking systems, warehouse shelves offer a lower cost route to achieving organised storage capacity – particularly useful for growing businesses that need greater storage density now without committing to a full scale storage overhaul.

Flexibility and scaling

Shelving systems, especially boltless and adjustable types, scale with the business. Bays can be added, reconfigured, or repurposed as product ranges shift and SKU management gets more complex, with the ability to add shelves more cost effectively.

How to choose the right warehouse shelves for your layout

The right storage system for your warehouse layout depends less on what’s popular and more on these three factors.

Item size & weight:

• This determines whether you need light-duty shelving, industrial steel shelving, or something rated for extra heavy duty shelving loads. Capacities are usually determined by shelf capacity, but consideration also needs to be given to overall bay capacity and the distribution of weight.

Picking frequency:

• High frequency hand pick operations benefit when fast moving stock is positioned on shelves at waist to eye level with clear aisle access, while slower moving stock can sit higher or lower.

Space constraints:

• Where floor space is limited, mezzanine floors can add a second storage level above shelving or racking, effectively doubling usable space without extending the building. Add-on features such as pallet loading gates and goods scutes make fulfilment and replenishment operations faster and more efficient. Multi-tier shelving systems is also an excellent solution to utilising headroom space.   

Getting these three right before ordering anything avoids the common trap of buying a system that looks efficient on paper but doesn’t match how staff actually work the floor.

Safety & compliance

Shelving carries compliance responsibilities as much as pallet racking does, and it’s often overlooked because the loads feel lighter.

In warehouse and stockroom environments, safe working loads should be clearly labelled on bays of shelving, and staff need to know what that means in practice, not just in theory. Access routes between shelving runs should stay clear and be wide enough for trolleys or pickers to pass without squeezing past stock. Taller units, particularly multi-tier and longspan configurations, need proper anchoring to the floor or structure to prevent tipping under load or impact.

Routine checks can seem a mundane task, but they do matter. The HSE’s HSG76 guidance on warehousing and storage sets out the standards most UK operations are expected to meet, covering everything from load limits to manual handling around storage equipment. It’s worth building a copy into your safety documentation rather than an after thought.

Integrating your warehouse shelving & storage

Shelves in a warehouse application rarely work in isolation. The strongest layouts treat storage as one connected system which may include pallet racking for bulk storage, shelving units for hand-picked stock and pick and pack workflows, mezzanines for vertical space, and picking stations positioned where the flow actually happens.

Thinking about these elements together, rather than sourcing them separately, tends to produce a layout that holds up as volumes change. That’s the difference between a warehouse that’s been fitted out and one that’s been designed – creating smarter spaces that keep pace with a growing business, not just a snapshot of where it is today.

Talk to BSE UK about your shelving

Every warehouse carries its own mix of stock, space and picking patterns, and the right shelving setup follows from that — not the other way round. If you’re weighing up boltless against longspan, working out where shelving should give way to racking, or planning a layout around a mezzanine, it’s worth talking it through.

Get in touch with the team at BSE UK:

Call: 0117 955 5211 Email: info@bse-uk.co.uk

The post Warehouse Shelving Solutions For Small & Medium Inventory appeared first on BSE UK.

Running out of space is one of the most common problems warehouse managers run into when they are in the process of expanding. The first thought many have is to buy more space – but this isn’t always necessary.

Running out of space can encourage bad practices in storing stock – leading to damaged inventory, missed orders and potential injuries.

In this post, we’ll run through a couple of procedures you can put in place and products you can implement to maximise space in your warehouse without the need for expensive extensions.

Rethink Your Warehouse Layout

Most warehouses are not configured with much thought to future expansion, which can lead to chaos when the time comes.

If you feel like you may run out of space soon or are already pushing against the walls of your warehouse, put some time aside to consider a new layout for your warehouse – this will take planning and may cause some down time so it's best done when you are experiencing a quieter period.

Our top considerations when redesigning warehouse space include:

• Use a map or blueprint of your warehouse to ensure accurate measurements are used when considering a new layout.
• Create separate spaces for loading and unloading.
• Consider the needs space requirements of warehouse workers and equipment such as forklifts.
• Get input from warehouse workers who will be familiar with the current system and any problems with it.
• Don’t neglect safety. For example, failure to leave adequate space between racking systems can increase the risk of rack damage.
• Create a separate area for order picking.
• Consider the flow of goods around your warehouse. If workers are traveling unnecessarily long distances between two areas, it could be a sign that your warehouse space is not optimised as well as it could be.
• Research proven warehouse layout designs. The most common are U shaped, I shaped and L shaped.
• Consider both horizontal and vertical space.

If layout changes are required, steel partition systems are an effective and affordable solution for redesigning the layout of your warehouse and can be used to create additional rooms including clean rooms, offices, break rooms and high security cages.

Analyse Your Inventory

When was the last time you carried out a full audit of your inventory? Carrying too much stock or keeping stock that you no longer sell takes up valuable space.

If you’re running out of space on your racks, conduct a full inventory audit and determine what stock you have in comparison to what you need, then move any surplus into storage.

Pallet Racking

Pallet racking is present in almost every warehouse, factory, fulfilment centre and other similar commercial premises, but did you know there are specialist types of racking available that can help maximise space when used correctly? Some of the most common types of racking and their benefits include:

• Adjustable Pallet Racking – Thanks to being easy to quickly assemble and disassemble, adjustable pallet racking can help you quickly readjust your layout to your needs to promote further growth. Adjustable pallet racking can be built up to 30m in height to make use of vertical space.
• Narrow Aisle Racking – Narrow aisle racking is taller and a lot narrower than conventional racking, it is a great way to get the most out of your space when used in conjunction with specialist narrow aisle forklift trucks.
• Drive In Racking – Drive in racking is designed to be used with a forklift and utilises the FILO (First In, Last Out) storage principle to increase available space by up to 100%. Drive in racking is an ideal solution for bulk storage of a single, non perishable product per lane.
• Double Deep Racking – Double deep racking enabled two pallets to be stored at each side of the system, effectively doubling available storage space versus a standard racking system.
• Multi Tier Racking – Multi tier racking systems span across multiple floors to utilise vertical space in the warehouse and increase your rack availability by 100% or more.
• Vertical Racking Systems – Vertical racing systems are specifically designed for more effective storage of tall items such as timber and pipework.

At BSE UK, we have many years of experience working with pallet racking systems and can design, supply, install and maintain racking from leading manufacturers as well as recommend the best racking for your requirements.

Mezzanine Floors

Instead of building out, build up! Mezzanine floors are the ultimate solution for making the most of often unused vertical space and can be used for additional storage space or to create new rooms entirely.

Mezzanine floors can be designed to suit your unique requirements and give your warehouse much needed additional space at a fraction of the cost of relocating or expanding.

At BSE UK, we offer a complete mezzanine flooring service including design, installation and ongoing maintenance. Our experienced team can also provide you with CAD drawings, structural calculations and obtain Building and Fire regulations approval on your behalf.

External Storage Solutions

If you have external space, don’t let it go to waste! External racking that is resistant to the elements can be installed outside of your warehouse to create more space in otherwise unused areas.

As well as creating more space, external racking is galvanised meaning it is robust enough to protect your stock in all weather conditions.

Temporary Solutions For Busy Periods

Temporary solutions such as shipping containers are a low-cost space solution; they can be particularly useful to store any surplus inventory you may have ordered in when preparing for a busy period such as Christmas.

If you are looking for a more permanent solution, a temporary warehouse or storage marquee may be lower cost alternative to expansion and perfect for dealing with excess stock during busy periods.

Train Your Staff

Almost all problems a warehouse manager encounters can be solved in part by properly training staff. If you have worked hard to maximise the space in your warehouse but your staff are unaware of racking weight limits and thus underloading them – your efforts will be wasted.

Training your staff to be more aware of the space available to them in racking and the warehouse, in general, will ensure that they are working with you and not against you to save space. Additionally, keeping your warehouse staff happy and motivated is a great way to encourage a good work ethos to ensure no space is wasted.

Load Your Pallet Racking Correctly

How much space is being wasted by under loaded or poorly loaded pallet racking? Ensuring that your pallet racking is loaded properly allows you to save space and load as much stock as safely possible. Be sure not to overload your racking, this can lead to racking damage and potential collapse.

Be sure that both you and your staff are aware of the maximum load your pallet racking can safely take by displaying weight load notices where appropriate.

Improve Your Warehouse with BSE UK

At BSE UK, we help our customers maximise their warehouse space to save them money and improve their productivity and efficiency.

We offer a range of warehouse storage solutions including pallet racking, mezzanine floors, shelving, partition systems and more to help you make the most of your existing space and avoid the high cost and disruption of relocation or expansion.

To find out more about how we can help call us today on 0117 955 5211 or book a free, no obligation site survey to arrange for a member of our team to visit your premises.

The post Maximise Space In Your Warehouse appeared first on BSE UK.

Optimisation of space usage is key to the success of any warehouse, and getting the most storage space from your racking helps improve efficiency all around.

Using the right kind of racking for different types of stock is imperative in achieving this, but sometimes awkwardly shaped stock can result in a number of problems including wasted space, damaged stock and difficulty for operatives when unloading; all of which reduce the overall efficiency of your warehouse.

Find out more about the different types of stock that can cause issues when it comes to storage, and the different types of racking that can be used to overcome these issues.

Storage for Long Bulky Items

Long and bulky items can cause all kinds of problems in the warehouse, with regular pallet racking not having adequate horizontal space to store or segregate long items.

An example of this is pipework: long, bulky and very heavy. The different sizes available may also mean that some segregation is required.

Solution – Cantilever Racking

Cantilever racking is an optimal solution for storing long and bulky stock, in addition to other items like carpet rolls, metal poles and other construction materials.

Unlike other racking systems, cantilever racking systems have no front uprights making loading and unloading easy, these systems also have very high loading capacities and are suitable for forklift truck and crane handling.

Storage for Long Fragile Items

Whilst Cantilever racking may seem the obvious solution for all long stock, it is not suitable in all cases. In some operations where stock is long but fragile, a cantilever racking system would not be the best choice as stacking can cause damage.

An example of this is timber, with some wood being fragile and coming in different types and sizes, stacking it up on a cantilever system could cause damage; the different lengths and types of timber could also throw up problems whilst trying to load and unload.

Solution – Vertical Racking

A vertical racking system is an effective type of racking for the storage of long fragile items, with items separated by adjustable beams to prevent damage from leaning and make for easier picking.

Read our case study for a vertical racking system installed at a timber company here.

Storage for Large Moveable Objects

Moveable stock is an entirely different beast when it comes to efficient storage. With the increased chance of items falling they are usually boxed up, this uses more space than necessary and creates delays when unloading stock.

An example of a difficult to store moveable item is vehicle tyres, stacking them on top of each other increases the risk of collapse, boxing them up wastes space and leaving them stored vertically allows them to roll which is dangerous for obvious reasons.

Solution – Dynamic Live Storage Racking System

A dynamic live storage racking system is a storage solution for these kinds of moveable objects, allowing for segregation of products, easy removal for pickers, forklift access and most importantly, flow technology – allowing for the safe and secure storage of moveable objects.

Once the stock is loaded in the gravity lanes on the loading side, they are carried down to the unloading side – once one is removed, another takes its place. This ensures that items are always available, and negates the need to stack or box moveable items.

Storage for Hazardous Items

It’s not just the shape but the nature of these items that makes them difficult to store.

For example, gas canisters - they are an awkward shape and storing them high up is potentially dangerous. However, keeping them at floor level could lead to a vehicle colliding with them, and storing them outside leaves them vulnerable to thieves.

Solution – Steel Mesh Cage

When it comes to storing hazardous items, there really is no excuse for half measures. Steel mesh cages are typically used to secure these kinds of stock, if your site is fairly secure you may consider constructing the cage outside to save space inside the warehouse.

Maximise Space In Your Warehouse

Whilst every warehouse will be different, we hope this blog post gave you an idea on which racking systems can be used to tackle some common offenders in the awkwardly shaped stock category.

If you’re struggling with awkwardly shaped stock, or want to ensure your maximising space in your warehouse – give one of our expert team a call on 0117 955 5211.

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