How many pallet positions fit in your hall, and what do your aisles cost you? Fill in the floor area, the hall length, your aisle width and how high you can go, and you see the positions you get and the square metres each one takes.
Only the area you can rack. Take the total and subtract docks, staging, packing benches, offices and any obstructed space.
The long dimension, the one your aisles will run along. Longer aisles mean fewer cross aisles and more positions.
Depends on your trucks: counterbalance needs about 3.5 to 4 m, reach trucks 2.8 to 3.2 m, narrow-aisle trucks 1.7 to 2 m.
How deep one rack row is, normally the pallet depth: 1.2 m for a euro pallet stored short side out. Use 2.4 m for double deep.
Pallet width plus the gap to its neighbour and a share of the upright. Around 0.9 m for an 0.8 m euro pallet.
Including the floor level. Limited by clear height, truck lift height and sprinkler rules, not just by the building roof.
4,224
Pallet positions
All levels counted.
Why this number: Slotting optimisation
The footprint before you go up.
How many rack blocks fit across the hall width.
Lower is a denser layout; multiply by your rent to price a position.
The rest is aisle. Typically 40 to 55 per cent is racked.
A one-page summary with your figures, the method and what the answer means.
Denser layouts mean more locations to keep track of, which is exactly where paper lists start costing you time.
See how location management worksIn plain terms: racking goes in as repeating blocks. Each block is two rows of pallets back to back with an aisle beside them, so a block is roughly two pallet depths plus one aisle width. Count how many blocks fit across the hall, how many pallets fit along its length, double it for the two rows, and multiply by how many levels high you go.
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Going from a 3.5 m to a 2.8 m aisle can add ten to fifteen per cent more positions to the same hall, but it commits you to different trucks and better floor flatness. Price the trucks before you price the racking.
One extra level costs beams and a taller mast; another thousand square metres costs rent forever. Check clear height and sprinkler rules first, because they, not the roof, decide how high you can actually store.
No, it models standard single or double deep pallet racking with aisles. Drive-in, push-back and mobile systems are denser but restrict access, so they need a layout designed around your product mix.
Cross aisles, columns, fire lanes and docks all eat into the plan. Reduce the usable area by ten to fifteen per cent for a realistic figure before you order steel.
Loading metres, floor area, volume and trailers needed, from your own pallet sizes and stacking height.
Volumetric weight calculatorDimensional weight, real weight and the chargeable weight your carrier actually bills.
Warehouse space calculatorSquare metres for a given number of pallet positions, including aisles and support space.
Loading metres, stock levels and order points are only as good as the stock data behind them. That is what a warehouse management system keeps accurate, every movement, without anyone maintaining a spreadsheet.
How many of your articles sit in a pick location they empty less than once a month?
Part one: Laying out a warehouse does not start with the racking
After your last integration, how many systems hold a stock quantity for the same item? Name them.