Case Study
Major Chilled Food Warehouse Storage Capacity Expansion in Cambridgeshire
Client
A large 3rd Party Logistics Company in the Chilled Food Sector
Location
Cambridgeshire
The Challenge
A leading third-party logistics (3PL) company operating multiple chilled food warehouses across the UK was facing increasing demand from customers and needed to maximise the efficiency of its existing warehouse space.
The business required a solution that would:
- Increase pallet storage capacity without expanding the warehouse footprint.
- Improve warehouse picking efficiency.
- Reduce picker travel distances.
- Improve outbound logistics processes.
- Enhance customer delivery performance.
- Create additional flexibility for future growth.
Like many food logistics operators, the client needed to optimise warehouse operations while maintaining fast-moving distribution schedules in a temperature-controlled environment.
Qubestor's Warehouse Storage Solution
Following a detailed warehouse assessment, Qubestor designed and installed a bespoke 2,000-pallet live storage dispatch system tailored specifically to the client’s chilled distribution operation.
The solution centred around relocating pre-picked dispatch pallets from conventional pallet racking into a dedicated pallet live storage system.
This strategic redesign transformed the warehouse layout and unlocked substantial operational improvements throughout the facility.
Key Features of the Solution
- 2,000-pallet live storage dispatch system.
- Dedicated dispatch marshalling area.
- Optimised warehouse flow.
- Improved access to outbound loading bays.
- Increased availability of standard pallet racking locations.
Enhanced picking zone configuration
The Results
INCREASED WAREHOUSE STORAGE CAPACITY
By transferring dispatch pallets into the new pallet live storage system, dispatch capacity increased from 700 pallets to more than 2,000 pallets.
This released approximately 1,300 pallet locations within the existing standard pallet racking system, significantly increasing overall warehouse storage capacity without requiring additional building space.
IMPROVED PICKING EFFICIENCY
Removing dispatch stock from storage and picking areas enabled the warehouse picking operation to be consolidated into a more efficient layout.
Benefits included:
- Shorter pick routes.
- Reduced picker travel times.
- Faster order fulfilment.
- Increased productivity.
- Improved labour utilisation.
The result was a more streamlined operation with quicker picking cycles and enhanced throughput.
FASTER OUTBOUND LOGISTICS PROCESSES
The increased dispatch capacity allowed outbound loads to be marshalled much earlier in the process and positioned closer to the dock levellers.
This improved the efficiency of vehicle loading operations by:
- Reducing congestion in dispatch areas.
- Improving workflow management.
- Accelerating loading times.
- Enabling better transport scheduling.
- Supporting on-time customer deliveries.
ENHANCED CUSTOMER SERVICE LEVELS
With greater storage capacity, improved picking performance and more efficient dispatch processes, the client was able to strengthen service delivery to customers.
The improved warehouse operation supported:
- Faster order processing.
- Greater operational reliability.
- Improved delivery performance.
Increased capacity to manage peak demand.
Project Outcome
Qubestor delivered a tailored warehouse storage solution that successfully transformed the client’s chilled food distribution operation.
ACHIEVED BENEFITS
✅ Increased storage capacity by 1,300 pallet locations
✅ Expanded dispatch capacity from 700 to over 2,000 pallets
✅ Improved warehouse picking efficiency
✅ Reduced pick walk distances
✅ Faster dispatch and loading operations
✅ Enhanced customer delivery performance
✅ Maximised existing warehouse space without expansion
