How DEVA helped a client increase its storage capacity by up to 30% with a double-deep racking system

In many cases, the real challenge lies in how that space is used.

One of our clients operated a warehouse with a wide variety of materials but no structured storage system. Most of the inventory sat directly on the floor, which made products hard to locate, limited the available capacity and reduced visibility of actual stock.

The client needed to increase the number of storage positions without expanding the facility while keeping an adequate level of access to the different materials.

The challenge

Before the project, the operation faced three main problems:

• Lack of order and poor vertical space utilization.
• Difficulty locating and controlling materials.
• Insufficient capacity to keep up with the company’s growth.

In addition, because of the diversity of products, not all materials could be stored the same way. Some required pallets and others had to be placed manually on suitable surfaces.

The solution, therefore, could not be limited to installing racks. It was necessary first to understand how the entire operation worked.

DEVA’s diagnosis

The DEVA team analyzed the materials, the load dimensions, the product types, the handling equipment and the client’s operational needs.

Based on this diagnosis, a layout was developed and different storage alternatives were evaluated.

A conventional selective racking system could not reach the required number of positions within the available area. However, it was also important to avoid a solution that would excessively limit access to the different products.

After analyzing these conditions, it was determined that a double-deep racking system offered the best balance between capacity, operation and space utilization.

“It’s not enough for a client to ask for a double-deep system. First you have to understand how their warehouse works and whether the solution will be compatible with all their activities.”

The solution implemented

DEVA designed a double-deep racking system adapted to the client’s real needs.

The project included:

• A layout designed specifically for the operation.
• The definition of load capacities and dimensions.
• Wire mesh decking on certain levels to store materials without pallets.
• A review of the clearances needed for the handling equipment.
• Consideration of tolerances, heights and possible growth needs.

The solution made better use of both the available area and the warehouse’s height.

In this project, the system increased storage capacity by approximately 25 to 30% compared with a conventional selective racking configuration.

This result reflects the specific characteristics of the operation, since the actual increase depends on the layout, aisle width, available height, the forklift and the inventory profile.

The results

The implementation didn’t just increase capacity.

It also transformed the way the client managed its inventory.

Among the main results were:

• Greater order within the warehouse.
• Better location and control of materials.
• Better storage and preservation conditions.
• Reduced risk of shrinkage.
• Greater visibility of actual stock.
• Space available to plan for future growth.

During the organization process, the client even identified materials it didn’t know it had.

This revealed that it held inventory of products it regularly bought again, simply because it didn’t know they were already available in stock.

“Order doesn’t just help make better use of space. It also helps reduce shrinkage, control inventory and know the warehouse’s real capacity.”

The key lesson

Before the project, the client believed its warehouse was practically full.

However, once the materials were organized within the new system, it discovered that it still had a significant amount of space available.

The problem wasn’t just physical capacity.

It was the lack of structure, visibility and control.

Thanks to the project, the client was able to move from an operation based on materials stored on the floor to an organized, measurable operation ready to grow.

When does a double-deep racking system make sense?

Double-deep racking can be an excellent option for increasing storage capacity, but it is not suitable for every operation.

Before implementing it, you need to analyze:

• Product diversity.
• The number of pallets available per SKU.
• Picking frequency and method.
• Inventory turnover.
• The level of access required.
• Load capacities and dimensions.
• The type of forklift required.
• Future growth plans.

It is also important not to assume that a double-deep racking system will automatically double capacity.

The real gain depends on the end-to-end design of the warehouse.

More than installing racks

The value of a storage project doesn’t lie only in the steel structure.

It lies in understanding how the operation works, how inventory moves and what the client needs to grow.

At DEVA, we don’t just install racks.

We design storage solutions that integrate space, inventory, handling equipment and operational processes.

Because when a warehouse seems to have no more capacity, the next step isn’t always to grow in square meters.

Sometimes, the next step is to design it better.