Every so often, a project comes along that’s not only rewarding, but also a lot of fun to be part of. A few years back, a unique project with BrewDog Brewing in Canal Winchester, Ohio definitely fits that description! What started as a single, small Pallet Rack order turned into a large, multi-stage pallet racking installation that supported both their production needs and their customer-facing space.

Before the project even began, we initially coordinated with BrewDog’s team headquartered in Scotland, which added another unique layer of communication and planning. Their team was fantastic to work with and helped set the foundation for the early stages of the installation before everything shifted to the Canal Winchester location.

If you’ve ever been inside BrewDog’s facility, you know it’s a busy place… constantly moving product, constantly growing, and always looking for ways to operate more efficiently. That meant they needed storage solutions that could keep up with their pace, but also give them the flexibility to expand as their needs changed. Instead of ordering everything at once, BrewDog purchased their pallet rack in stages, adding on as new areas were built out and as the brewery continued to scale.

A Project That Grew Alongside the Brewery

The first phase focused on back-of-house storage. We installed heavy-duty pallet racking to help them organize incoming ingredients, packaged beer and brewery equipment. With the amount of product they move in and out each week, improving the flow of materials was a high priority. The new racking immediately made a difference by giving them more vertical storage and reducing clutter on the warehouse floor.

As the project continued, BrewDog expanded their front-of-house retail space. They wanted racking solutions that looked clean and professional but were sturdy enough to hold cases, merch, and seasonal items. We matched the design to their existing layout so everything looked intentional, not just functional.

Each new stage added another layer to the overall footprint, and before long, the job evolved into a very large installation. By the final phase, the system we had built together supported a wide range of operational needs, from production to retail.

Teamwork, Flexibility and a Great Partner

One of the most enjoyable parts of this project was the collaboration. BrewDog knew what they needed, and we helped them figure out the safest and most efficient way to achieve it. Timing was important, and since they were purchasing racking as needed, we made sure each phase was scheduled and installed in a way that didn’t slow down their daily operations.

It’s always rewarding to step back at the end of a project like this and see how much the space has transformed, especially knowing the system will support BrewDog’s growth for years to come.

A Look Ahead…

Whether it’s a small add-on or a large multi-stage installation like this one, we take pride in helping businesses build storage systems that actually work for the way they operate. BrewDog was a great partner throughout the process, and we’re proud to have played a small role in their continued success in Canal Winchester.

If your business is expanding or you’re considering updating your storage layout, allow the team of experts at Midwest Material Handling, LLC to help you explore the options!

From a buyer’s perspective this has always been a difficult and often times confusing decision. Let’s first briefly discuss the advantages of purchasing USED Pallet Racking.

Advantages

Obviously, the overriding thought when considering purchasing USED Pallet Racks is cost. A secondary, but equally important benefit is the USED equipment is on-site and available immediately, saving time and freight costs.

Now for the reality… Many buyers wrongly think that purchasing USED Pallet Racking and Wire Decking is similar to that of purchasing a used car (for example), that there is a 50% or 60% savings over the cost of NEW. Unfortunately, this is rarely the case.

Let’s discuss why…

When we are contacted by a seller who has USED equipment available, the vast majority of the time, the racking is still standing and needs to be disassembled. Once we send a crew into disassemble the Rack, we then need to stack, band and prep it for shipment. Once complete, the USED Pallet Rack needs to be shipped, via flatbed to our location. Due to its size and length, USED Rack/Wire Decks are generally stored outside, allowing the powder coated finish to begin rusting and oxidizing. One item of note, many buyers have little regard for the discoloration or aesthetic appearance of the USED Racking, they simply want it to work! Add all of that up and the NEW vs. USED savings is somewhere in the vicinity of 15%-20%.

Damage

One other very important consideration… historically, we have rarely sold USED Pallet Rack Uprights as they generally have some sort of column damage (probably 4 out of 5 Uprights sustain damage from forklift forks or skids) usually located at the lower 12”-24” of the two front Upright columns. * NOTE: If there is ever a ding or dent in an Upright… BUYER BEWARE! The structural integrity of the Upright has been compromised and the Upright should be discarded. There are disreputable companies and social media sellers out there that will sell them, but we won’t (and you should not buy them)!

Condition

While we stock and sell a significant amount of USED equipment (primarily Pallet Rack and Wire Mesh Decks), the quality and condition of the USED equipment we sell is exceptional. We only sell USED material that has an overall condition rating of 8-9 out of 10, we do not sell anything with any lower condition rating. All of our USED Racking has a condition rating applied to it at arrival and is always furnished and noted on our proposals. Of course, pictures are always available when the Racking cannot be viewed in person or we are shipping it out of area. You can always trust our condition ratings to be accurate and thorough.

Modern manufacturing techniques have improved to the point that, many times, purchasing NEW can actually be less expensive than buying USED. Even more so, the same holds true for USED Pallet Rack purchased at auctions or auction settings, but that’s a conversation for another day. Additionally, another great geographical advantage he have is the majority of our NEW Wire Mesh Deck Panels are manufactured (ITC Manufacturing) right here in Columbus, Ohio! Pick them up and save the freight!

For more information on New and Used Pallet Racking, check out… https://mmhonline.com/selective-pallet-rack-ohio/

Warehouse efficiency is often discussed in terms of automation, robotics, or complex software systems. While those technologies certainly play a role, one of the most important factors is much simpler: how the warehouse is physically organized.

The layout and design of storage racking systems determine how easily inventory moves through a facility. When storage is poorly planned, forklifts travel farther than necessary, aisles become congested, and valuable floor space is wasted. A well designed racking layout can dramatically increase storage capacity while making everyday operations faster and safer.

For many warehouses, improving efficiency does not require expanding the building. It simply requires making better use of the space that already exists.

Why Storage Layout Matters More Than Most People Think

Walk through any busy warehouse and you will notice that most of the activity revolves around moving pallets. Forklifts are constantly retrieving, storing, and repositioning inventory throughout the facility. If the storage layout is inefficient, every one of those movements takes longer than it should.

Even small improvements in storage design can make a noticeable difference. Shorter travel distances, clearer aisle access, and better organization all contribute to smoother operations.

Well planned racking systems also make inventory easier to manage. When pallet positions are clearly defined and easy to access, employees spend less time searching for products and more time moving orders out the door.

High Density Storage Is Becoming More Important

As inventory volumes increase and industrial real estate becomes more expensive, warehouses are looking for ways to store more product within the same footprint.

High density racking systems are one of the most effective solutions. These systems reduce the amount of aisle space required and allow pallets to be stored deeper within the rack structure.

Drive in rack systems allow forklifts to enter the rack structure and store pallets several positions deep. This approach works well when large quantities of the same product are being stored together.

Pushback racking uses a system of nested carts that allow pallets to be stored multiple positions deep while remaining accessible from the aisle. As pallets are removed, the remaining pallets roll forward into position.

Both systems allow warehouses to significantly increase pallet capacity compared to traditional single deep storage layouts.

Flexible Storage Systems Support Changing Inventory

Warehouse operations today are rarely static. Product lines change, inventory levels fluctuate, and order volumes shift throughout the year.

Adjustable racking systems help facilities adapt to those changes. Beam levels can be repositioned to accommodate different pallet heights, and sections of racking can be modified as storage needs evolve.

This flexibility allows warehouses to adjust their storage layout without major construction or facility expansion.

Technology Is Supporting Smarter Warehouse Operations

Modern warehouses are also benefiting from improved technology. Warehouse management systems provide real time visibility into inventory levels and product locations. Scanning systems reduce errors during receiving, picking, and shipping.

Some larger operations are also exploring robotics and automated picking systems to handle repetitive tasks more efficiently.

However, even the most advanced technology still depends on a well organized storage layout. When storage systems are designed properly, both employees and automated systems can work faster and more efficiently.

The Right Storage System Makes a Long Term Difference

Improving warehouse efficiency rarely comes from a single change. Instead, it usually comes from combining better storage systems, improved workflow design, and the right equipment.

A well planned racking layout can increase pallet capacity, reduce congestion, and improve overall productivity without expanding the building.

For a closer look at different warehouse racking configurations and storage options, visit our page covering warehouse pallet racking systems and storage solutions.