Midwest Material Handling developed the concept, design and layout for a large scale pallet rack supported pick module system for a major international auto glass manufacturer in Mobile, Alabama. Working in collaboration with engineering support from Interlake Mecalux, the system was structurally engineered and then installed by our team to create a high density storage solution capable of organizing and picking more than 9,100 SKUs within a limited warehouse footprint.
The success of this design led to the system being duplicated at additional service center locations throughout the United States, creating a standardized storage model for regional operations.
Project Scope and Requirements
The facility handled a wide range of windshield and specialty glass products with varying dimensions and weights. SKU count exceeded 9,100 active items, and available floor space did not allow for horizontal expansion.
Key requirements included:
• High density SKU organization
• Efficient hand picking access
• Structural support for a mezzanine platform
• Long clear spans for oversized glass products
• Scalable design for replication across multiple facilities
Traditional shelving would not provide sufficient structural capacity. A conventional pallet rack layout alone would not deliver the SKU density required for manual picking operations. The solution required an engineered integration of rack structure and wide span shelving.
System Engineering and Design Collaboration
Midwest Material Handling developed the initial layout concept, storage configuration and operational flow strategy for the pick module system. Interlake Mecalux provided structural engineering support to ensure load calculations, rack frame performance and mezzanine integration met required specifications.
The system was built around standard roll formed pallet rack uprights and beams that served as the primary structural framework. These rack frames supported a mezzanine platform, creating a second level of storage without increasing building footprint.
Above the mezzanine level, wide span shelving was installed to store lighter but oversized truck windows and specialty glass components. The extended beam spans allowed clean SKU separation and open hand access while supporting required load capacity.
Because the system was engineered as a repeatable model, it could be adapted and duplicated across additional service center locations with consistent structural and operational performance.
For more information on this storage solution, visit our Wide Span Shelving in Ohio page.
Multi Level Access
An external stairway was incorporated into the pick module to provide convenient access between the warehouse floor and the elevated storage levels. Positioned along the outside of the rack supported structure, the stairway allowed personnel to move efficiently between levels without interfering with picking and storage areas.
The stairway was integrated into the overall system layout along with the mezzanine platform, rack structure and shelving. Its placement provided a dedicated access point while maintaining usable storage space throughout the pick module.
Pallet Loading Gate
A pallet loading gate was incorporated into the elevated platform to provide a designated point for moving materials between levels. The yellow safety gate creates a controlled opening at the platform edge while maintaining a protected working area when the loading point is not in use.
Positioned along the outside of the pick module, the loading gate allowed materials to be transferred to the elevated storage level without requiring access through the primary personnel stairway. Integrating the gate into the overall system layout helped support efficient material handling while maintaining separation between picking areas and the material transfer point.
Installation and Execution
Midwest Material Handling managed on site installation, structural coordination and full system integration. Due to the size and complexity of the project, installation required nearly one month of coordinated field work to complete.
Careful attention was given to:
• Structural load distribution across rack frames
• Mezzanine attachment and alignment
• Beam span selection for oversized product storage
• Multi level structural consistency
• Safe and efficient vertical access
Completing a project of this scale within an operational industrial facility required disciplined sequencing, crew coordination and strict adherence to engineered specifications.
Operational Results
The completed pick module system delivered measurable improvements in storage density and picking efficiency. By building vertically rather than expanding outward, the facility significantly increased usable storage capacity within the existing footprint.
Results included:
• Organized storage for more than 9,100 SKUs
• Improved vertical space utilization
• Reduced picker travel distance
• Clear separation of oversized and specialty products
• A scalable system design implemented at additional service centers nationwide
By combining pallet rack structural support with wide span shelving storage levels, the facility achieved high density organization while maintaining safe and efficient hand access.
Engineered Pick Module Systems
Pick modules are engineered storage systems built around rack supported platforms and multi level shelving. They are commonly used in high SKU environments where picking accuracy, accessibility and vertical utilization directly impact operational performance.
Midwest Material Handling develops layout concepts, collaborates with manufacturer engineering teams and installs integrated rack supported pick module systems tailored to inventory profile, SKU count and facility constraints.
To learn more about our broad storage rack solution, visit our pallet rack and storage rack systems page.
Frequently Asked Questions (FAQ’s)
What is a pallet rack supported pick module?
A pallet rack supported pick module is a multi level storage system that uses pallet rack as the primary structural framework. Platforms and shelving are incorporated into the rack structure to create additional picking levels without expanding the building footprint.
How many SKUs can a pick module accommodate?
Capacity depends on the facility layout, product dimensions, storage requirements and number of levels. The system described in this project was designed to organize and support picking for more than 9,100 SKUs within a limited warehouse footprint.
Can pallet rack support a mezzanine or second level?
Yes. Properly engineered pallet rack systems can support elevated platforms and multiple levels of storage when designed for the required loads. Structural engineering is important to ensure the rack, platform and connections are properly designed for the application.
Can a pick module be designed for oversized products?
Yes. Pick modules can incorporate wide span shelving and longer beam spans to accommodate products that are too large for conventional shelving. In this project, wide span shelving was used above the mezzanine level to organize oversized truck windows and specialty glass products.
Does Midwest Material Handling install pick module systems?
Yes. Midwest Material Handling provides installation and system integration for pallet rack and multi level storage systems. For larger engineered projects, we can also coordinate with rack manufacturer engineering teams to develop a system that meets the required structural specifications.
Can the same pick module design be used at multiple facilities?
Yes. One advantage of a properly developed pick module concept is that it can be standardized and adapted to other facilities. The system featured in this project was subsequently duplicated at additional service center locations throughout the United States.
