Question 1

Do you handle warehouse layout and design?

Accepted Answer

Yes. Our engineers use advanced CAD and slotting software to develop complete layout and traffic-flow plans—covering receiving, storage, picking, packing, and shipping—so every square foot is used efficiently and future growth is built in from day one.

Visit our Layout and Design page to learn more.

Question 2

Do you provide warehouse layout design drawings we can hand to installers?

Accepted Answer

Yes. Our warehouse layout & design team delivers full CAD drawing packages that you can hand directly to installers, contractors or permitting officials. These installation-ready blueprints ensure every rack, conveyor and safety component is placed exactly as engineered.

Warehouse Cubed’s warehouse consulting services begin with a detailed site assessment, then move into layout strategy using advanced CAD software. We convert those digital models into installation-ready drawing sets that include:

Scaled floor plans showing aisle widths, pick zones, pallet racking systems, conveyors, mezzanines and safety barriers.
Elevations and section views with rack heights, beam levels and capacity labels.
Anchor-bolt and seismic details stamped by a licensed engineer when required.
Bills of material and part labels that match every position on the drawing.

Automation modules—like conveyor merges, sorters or AS/RS pick stations—are plotted in the same files so material handling systems integration is seamless. Because installers work from clear, standardized sheets, projects move faster and with fewer field modifications. If you prefer, Warehouse Cubed can coordinate turnkey installation; many clients simply hand our drawings to their own crews and stay on schedule.

Beyond the initial build, these drawings become a living reference for future expansions, rack repair or warehouse safety audits, and they simplify permitting because all clearances, egress paths and fire-code requirements are documented up front.

Whether you need a new distribution center layout or a targeted reconfiguration, our design packages give your installers the roadmap they need for a flawless, code-compliant build.

Question 3

How do I redesign a warehouse layout to reduce picker travel time?

Accepted Answer

Begin with a data-driven slotting analysis, group high-velocity SKUs near packing, shorten aisles, and add pick-to-light conveyors or AS/RS. Warehouse Cubed uses CAD layout design to reposition racks, create clear one-way pick paths, and integrate automation so your pickers walk less and ship orders faster.

Reducing picker travel time starts with facts, not guesses. Warehouse Cubed’s warehouse consulting services begin by downloading twelve months of order history into our slotting software. We calculate SKU velocity, cube size, and order affinity to decide which items deserve golden-zone positions closest to your packing stations. Next, our warehouse layout design team builds a 2-D and 3-D CAD model that right-sizes each pick face and lays out one-way traffic aisles to eliminate cross-flow congestion.

High-volume SKUs are positioned at ground level on pallet racking systems; slower movers are pushed upward or into dynamic carton flow, keeping the pick window tight. For long pick walks, we integrate conveyor systems or pick-to-light zones so employees touch product, not miles of concrete. When SKU counts explode, automated storage and retrieval systems (AS/RS) or vertical lift modules can shrink walk time to seconds while increasing storage density.

The redesign also pays attention to safety: wider end-of-aisle turn zones, floor striping, and protective guarding keep people and forklifts separated. Because every facility is unique, we model several what-if scenarios—then our material handling systems integration crew installs the chosen plan over a weekend to avoid downtime. Clients routinely see 30-50 percent faster order fulfillment and labor savings that fund further warehouse automation solutions.

Question 4

What are the best tips for cold storage racking and condensation management?

Accepted Answer

Use corrosion-resistant racks, leave 3–4 inches between pallet loads for air circulation, install insulated column guards, and add ceiling fans or low-velocity air movers to prevent temperature stratification. Control humidity with tight door seals and properly sized dehumidifiers, and schedule routine rack inspections to catch rust or ice damage early.

Cold rooms challenge both steel integrity and worker safety, so start with the right pallet racking system. Choose galvanized, epoxy-coated, or stainless uprights and beams that resist corrosion from constant 0 °F temperatures and wash-downs. Warehouse Cubed’s pallet racking systems can be engineered for drive-in, push-back, or mobile configurations to maximize high-density freezer space without blocking airflow.

Layout matters just as much as rack finish. Leave at least 3 – 4 in. between pallet faces and a 12 in. gap from the back wall to keep evaporator coils unobstructed. Our warehouse layout design team models cold-air circulation and product turns so you can avoid temperature shadows that create condensation.

Moisture control begins at the dock. Specify high-speed doors with tight seals, insulated dock levelers, and vinyl air curtains to reduce warm, humid air infiltration. Where infiltration can’t be eliminated, add desiccant wheel dehumidifiers or glycol re-heat systems to keep relative humidity below 60 % and prevent frost on racks and floors.

Finally, build a preventive-maintenance routine. Schedule quarterly warehouse safety audits and pallet rack repair to identify rust, ice expansion, or forklift impact before they compromise capacity. Combine those audits with regular ice removal, defrost cycles, and LED lighting checks to keep your cold storage operation efficient, safe, and compliant.

Question 5

What is a pick module and when should I add one?

Accepted Answer

A pick module is a warehouse optimization solution; a multi-level rack and conveyor zone that feeds high-volume SKUs to pickers while bulk pallets sit above or behind. Add one when rising order lines, costly travel time, or limited floor space demand faster, denser order fulfillment without relocating or fully automating the entire warehouse.

A pick module is essentially a rack-supported mezzanine that funnels product from bulk storage to fast-moving pick faces. During layout design and distribution center optimization projects, we often deploy these modules to shorten picker travel and concentrate SKUs by velocity. Multiple levels of selective or pallet flow rack feed gravity lanes or conveyors so pickers can grab cartons quickly while replenishment happens behind the scenes. By stacking pick positions vertically, you multiply SKU capacity without expanding the building footprint.

You should consider adding one when e-commerce order lines are climbing, travel time dominates labor costs, or seasonal peaks strain floor-level shelving. A pick module is also ideal when you plan to introduce conveyor sortation or automated storage and retrieval systems (AS/RS) but need a phased approach. Warehouse Cubed’s warehouse optimization team can model throughput, design the racking, and integrate carton flow, conveyor systems, lighting, and safety guarding in a turnkey package. Because we handle material handling systems integration, permitting, and installation nationwide, you get one accountable partner and faster payback. Most clients recover the investment in 12–24 months through reduced labor, higher pick accuracy, and deferred building expansion.

Question 6

What is the best way to create quiet office space inside a noisy warehouse?

Accepted Answer

The quickest, most cost-effective way to carve out a quiet office inside a noisy warehouse is to install a pre-engineered modular in-plant office from Warehouse Cubed. Its insulated wall panels, sealed windows, and acoustic ceilings block forklift and conveyor noise while the modular design avoids messy traditional construction.

Start with a Warehouse Cubed warehouse consulting services audit to pinpoint the best location, typically along a perimeter wall or on a mezzanine to lift the office above the busiest traffic lanes. We then design a modular in-plant office built from high-density, sound-rated panels and gasketed connections that cut ambient noise by up to 30 dB.

Optional double-pane windows, solid-core doors, and acoustic ceiling tiles further improve speech privacy without sacrificing visibility. The entire structure ships as pre-finished panels, arrives with electrical raceways and HVAC penetrations in place, and assembles in days, not weeks, so production never stops.

Because the office is non-permanent, you can expand, relocate, or reconfigure it as your operation grows, perfect for distribution center optimization. Pairing the office with a Warehouse Cubed mezzanine lets you reclaim the floor below for pallet racking systems or conveyor systems, boosting storage density and workflow at the same time. Every installation follows OSHA and local code requirements, and our material handling systems integration team can link data lines, lighting, and climate control to your existing infrastructure.

The result is a quiet, climate-controlled workspace that keeps supervisors close to operations while protecting them from noise, dust, and safety hazards.

Question 7

What is the ideal aisle width for reach trucks vs forklifts?

Accepted Answer

Reach trucks usually need 8.5–10-ft wide aisles, while standard counterbalanced forklifts work best in 12–14-ft aisles. Choosing the tighter reach-truck layout boosts storage density but demands clear sight lines and good floor conditions. For forklifts, wider aisles allow safer turns and faster two-way traffic.

Warehouse layout design starts with the space between racks. For reach trucks, an 8.5- to 10-foot clear aisle lets the mast extend and retract without the wide swing of a counterbalanced chassis. This narrow-aisle approach can add 20-30 percent more pallet positions, making it popular in high-volume e-commerce facilities where every inch matters.

Conventional forklifts, by contrast, need about 12–14 feet to turn, tilt, and travel past oncoming traffic. The extra width improves visibility and reduces rack impact risk, which our warehouse safety audits show is a leading cause of unplanned downtime.

When Warehouse Cubed’s warehouse consulting services team models a new storage layout, we compare equipment specs, load size, and pick velocity to balance density and flow. If you want to shrink aisles for reach trucks, we often pair them with higher pallet racking systems, wire-guided paths, and floor flatness testing to keep operators efficient and safe. Where wider forklift aisles remain necessary, such as staging heavy outbound loads, we create hybrid zones, add protective guarding, and mark clear travel lanes.

The result is a material handling systems integration plan that maximizes cube utilization today while leaving room for future automation like automated storage and retrieval systems. Visit our Layout and Design page to learn more about how we can support your business.

Question 8

What’s the best strategy to reclaim vertical space safely in a low-clearance building?

Accepted Answer

The safest way to reclaim vertical space in a low-clearance warehouse is to install a custom, low-profile mezzanine or rack-supported catwalk system designed to fit beneath roof obstructions, combined with narrow-aisle pallet racking and a full safety package—guardrails, gates, signage, and a code-compliant sprinkler plan.

Start with a professional warehouse safety audit and layout review. Warehouse Cubed’s warehouse optimization team measures clear height, column spacing, sprinklers, and egress routes, then models options in 3-D CAD. In low-ceiling buildings (12–18 ft) we usually specify a low-profile structural or rack-supported mezzanine that adds a second level for light pick, packing, or small-parts storage while preserving forklift clearance below. See our Mezzanines page for examples. Using bar-grating and slim 4-in. beams keeps deck depth to a minimum, gaining up to 85 lb/ft² live load without raising the roof.

Under the platform we re-slot inventory in selective or push-back pallet racking sized exactly to the remaining headroom. Narrow-aisle reach trucks or pallet shuttles improve cube utilization by up to 40 %. Where ceiling height is under 16 ft, vertical lift modules or horizontal carousels deliver automated storage and retrieval systems (AS/RS) that hold thousands of SKUs in a 10 × 20 ft footprint.

Every mezzanine ships with OSHA-rated guardrails, self-closing pallet gates, kick-plates, and clearly posted capacity signs; optional VRC material lifts eliminate manual carrying. Our material handling systems integration crew installs the structure over a weekend so you avoid long shutdowns, and we provide ongoing pallet rack repair inspections to keep it safe. Result: more pick faces, safer traffic flow, and a fast ROI without expanding your building.

Layout & Design