Manufacturing
Manufacturing Warehouse Storage Solutions
Storage systems designed for production flow: raw material staging, work-in-process buffers, finished goods storage, and oversized parts handling.
4,417
Pallet positions plus 1,096 pick levels, consolidating several warehouses into one (Fayetteville, AR)
6 Days
Pallet rack, cantilever and shelving installed after an on-site redesign (Winston-Salem, NC)
High-Pile
Storage permit secured to use the building's full height (Carrollton, TX)
106
Cantilever bays for trusses and long stage components (Lititz, PA)
Manufacturing warehouse storage requires racking systems that support the flow of raw materials, work-in-process staging, finished goods inventory, and oversized parts unique to production environments. Manufacturing facilities often combine cantilever racks for long stock, selective racking for finished goods, and heavy-duty shelving for tooling and components.
What We Understand
The Challenges Specific to Manufacturing
Mixed Inventory Types in One Facility
Manufacturing facilities store fundamentally different things in the same building: raw materials, work-in-process, finished goods, tooling, and packaging supplies. Each has different weight profiles, access frequencies, and rotation requirements. A single racking configuration doesn't work. We design zone-by-zone, matching the storage system to each inventory type.
Oversized and Irregular Loads
Bar stock, sheet metal, tubing, dies, and finished assemblies don't fit on standard pallets. Cantilever rack, custom beam levels, and wide-bay configurations handle irregular shapes and heavy unit loads without wasting aisle space or creating safety problems. We size every system to your actual load profiles, not catalog assumptions.
Production Flow and Line-Side Staging
Storage that's disconnected from the production floor creates bottlenecks: forklifts running long distances, staging areas overflowing, production lines waiting on material. We design layouts that position raw materials and WIP buffers close to the lines they feed, reducing travel time and keeping production moving.
Our Approach
Designed Around How Your Production Floor Actually Works
We start every manufacturing project by walking your facility: understanding material flow from receiving dock through production lines to finished goods shipping. The storage layout follows the production workflow, not the other way around.
Raw material zones get the system that matches the material type: cantilever for long stock, selective rack for palletized inputs, and drive-in for high-volume bulk items. WIP staging areas are positioned close to the lines they feed. Finished goods zones are configured for outbound efficiency, whether that's selective rack for mixed-SKU picking or push-back for bulk shipment staging.
All installations are coordinated around your production schedule. Phased installs across nights, weekends, or facility sections keep your lines running throughout the project.
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Recommended Systems
Storage Solutions We Commonly Install for Manufacturing
Cantilever Rack
Open-front arm storage for bar stock, sheet goods, tubing, lumber, and other long or oversized materials that don't fit on standard pallet rack.
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Selective Pallet Racks
Direct access to every pallet position. The workhorse for finished goods, raw material pallets, and WIP buffers where selectivity and access speed matter.
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Guardrails & Barriers
Machine guarding, work-cell perimeters, and floor-anchored barriers separating production equipment from material handling traffic.
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What This Looks Like in Practice
Carrollton, TX · 420 Pallet Positions · Completed 2025
Selective Racking for Plastics Manufacturer
Selective pallet racking installation for a plastic fabrication and PVC pipe fittings manufacturer in Carrollton, TX. Hammerhead designed the layout, secured a high-pile storage permit to safely maximize storage height, and completed installation on schedule despite DFW power outages, delivering 420 pallet positions and an immediate jump in operational efficiency.
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Fayetteville, AR · 4,417 Pallet Positions · 2 weeks
New Facility Pallet Rack Installation
Large-scale selective pallet rack installation for a full-service construction company, delivering 4,417 pallet positions and 1,096 pick levels across a new facility, roughly 400,000 pounds of customized steel racking. The system provides dedicated palletized storage for oversized items alongside hand-stack pick levels for smaller parts, all reinforced with rack protection accessories and engineered to structural compliance standards.
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Winston-Salem, NC · 23,000 sq ft · 504 pallet positions · 6 days
Mixed Storage Solutions for Recycling Equipment Manufacturer
Multi-system storage installation for a recycling plant manufacturer, combining selective pallet racking, cantilever racks, and shelving to organize both large components and small parts across their production facility. The project delivered 504 pallet positions, 77 shelf levels, and 66 cantilever levels, all protected with rack safety accessories and backed by structural engineering for long-term compliance.
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Manufacturing plants can't shut down a production line for a rack install. We phase the work so operations keep running, section by section. The goal is more storage capacity without any lost production time.
Dylan Andrews
VP Operations, Hammerhead Warehouse Systems
Related Industries
Planning a Manufacturing Storage Project?
We'll assess your facility and design a layout that supports your production flow. Free consultation, no obligation.
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