West Pennine initiated discussions with Alliance, a Worcestershire-based carpet company, in 2018 when they were considering racking solutions for an existing property. However, plans shifted, and Alliance decided to construct a new facility. West Pennine remained a key partner, providing racking solutions for the vast space intended to store 25,000 rolls of carpet and accommodate an additional 2100 pallets. The comprehensive project spanned 12 months of planning and three months of installation, with regular on-site visits by senior leadership to ensure seamless progress.
The initial stage involved working closely with the building contractor to understand the column layout of the structure. After the building’s construction, our planning team took precise measurements. These were crucial to prevent cumulative errors in the extensive space. With column distances of about 100 meters, we ensured an optimal racking solution, strategically placing timber around building uprights to safeguard against potential damage.
A significant challenge was managing the 150-meter racks efficiently due to the length of the warehouse. To do this, we introduced 3.9-meter bridge bays at intervals, enhancing forklift accessibility and reducing travel distances within the facility. Collaborating with Alliance, locations for these bays were meticulously agreed upon for maximum operational efficiency.
The project also had to navigate the business’s carpet cutting and sortation machines. Adjustments were made, including extending a rack to align with the machines. A heavy duty structural steel frame was installed above these machines for additional storage. As the structure needed to be secured to the floor, we needed to work with the building contractor to ensure pre drilled holes were included that matched the pallet racking footplates. This allowed for the rack to be bolted on top of the structure.
The project encountered unforeseen challenges, such as the need to avoid expansion joints in the floor. Detailed drawings were provided to the flooring contractor, ensuring efficient bay lengths and saving time on redesigns.
Also, to address safety concerns associated with back-to-back racks, our team installed net curtains between them, preventing products from being pushed through to the opposite side. Additionally, over a kilometre of bump rails were installed along rack fronts to guide forklifts safely.
Supply chain disruptions posed another hurdle, with the war in Ukraine affecting timber and steel prices. Our procurement team navigated these challenges by shifting timber sourcing to Scandinavia, ultimately providing Alliance with a firm cost once stability returned to the supply chain.
The collaboration between West Pennine and Alliance resulted in a meticulously planned and executed storage solution. Overcoming unexpected challenges showcased our adaptability and commitment to ensuring an efficient, safe, and cost-effective racking system for Alliance Carpets. The successful completion of this project underscores our expertise in providing tailored storage solutions for diverse industrial needs.
UK Market Leading Solutions
West Pennine Storage Equipment are proud to be a Tier One design and installation partner for Link 51 and Apex Linvar. Our relationship with Link 51 and Apex allows us to design, deliver and install the highest quality, UK-manufactured racking at competitive prices. As we are a highly recognised distributor of all storage facilities, we are also able to supply all other major brands of Pallet Racking, Industrial Shelving and other Storage Systems.
