Warehouse Distribution
Warehouse Distribution Storage Solutions
Storage systems designed for throughput: maximizing pick efficiency, pallet positions, and operational flow in distribution operations.
10–15%
Lower forklift travel time with strategic slotting
30–50%
More pallet positions in the same footprint
99.5%+
Inventory location accuracy with dedicated positions
20–35%
Pick rate improvement with optimized slotting
Warehouse distribution centers require storage systems optimized for high throughput, rapid order fulfillment, and efficient use of vertical space. Racking configurations in distribution facilities typically combine selective pallet racks for fast-moving SKUs with pick modules, carton flow, and conveyor integration for multi-channel shipping operations.
What We Understand
The Challenges Specific to Warehouse Distribution
Balancing Density and Accessibility
The wrong balance between density and accessibility kills throughput and drives up labor costs. You need enough pallet positions for inventory depth, but the layout has to support efficient pick paths, forklift traffic flow, and dock door utilization. We design for both.
Flexibility as Operations Change
Most facilities need flexibility: product mix changes seasonally, customer requirements shift, volume fluctuates. A rigid layout may not work 6 months later. We build reconfigurability in from the start: adjustable beam levels, modular bay designs, configurations that adapt as your operation changes.
Permitting Complexity and Tight Timelines
High-pile storage permits for distribution centers require technical documentation and fire marshal coordination. DC projects also have tight timelines. You need a partner who understands both the operational side and the structural and compliance side simultaneously.
Our Approach
Built for How Your Distribution Center Actually Operates
We start every DC project with a workflow review: understanding your pick profiles, forklift traffic patterns, dock door assignments, and growth projections. The rack layout follows the workflow, not the other way around.
We configure selective for high-SKU pick areas, push-back or drive-in for bulk reserves, and carton flow for case-level picking. Beam heights and aisle widths are set to your specific forklift fleet and pallet dimensions, not generic clearances. We build flexibility in from the start so when volume grows or product mix changes, the system adapts without a full teardown.
All installations are coordinated around your operational schedule. Phased installs across nights, weekends, or facility sections keep product moving throughout the project.
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Recommended Systems
Storage Solutions We Commonly Install for Warehouse Distribution
Selective Pallet Racks
Direct access to every pallet for high-SKU, high-selectivity distribution operations. The most flexible system for mixed-product DCs with frequent picking.
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Push Back Racking
2–6 pallet deep gravity lanes for higher density than selective rack with better selectivity than drive-in. Strong for reserve storage behind active pick lanes.
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Carton Flow Racks
FIFO case-pick flow for high-velocity order fulfillment. Speeds pick rates and reduces travel time in active pick areas.
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What This Looks Like in Practice
300,000 sq ft e-commerce distribution center in New Jersey : mixed system (selective for forward pick + push-back for reserve + multi-level pick module with integrated carton flow and conveyor), improved pick efficiency 30%, added 1,200 pallet positions, full permitting handled, phased installation completed on schedule.
Distribution is all about throughput. The right layout reduces travel time per pick, and that compounds across every shift, every day. We look at pick paths and order profiles before we spec a single rack, because the system should match how the operation actually moves.
Dylan Andrews
VP Operations, Hammerhead Warehouse Systems
Related Industries
Designing or Reconfiguring a Distribution Center?
We'll visit your facility and design a layout that maximizes both density and throughput. Free site visit, no obligation.
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