Combined racking system with automated mezzanine

Optimal solution for efficient storage

A regular client approached us with the task of developing a storage system for a 3400 m² warehouse area. The requirements included organizing storage for both palletized cargo and small items, while ensuring quick order picking. Our engineers developed a comprehensive solution combining a four-level mezzanine and Profi combined racking system. 

Automated mezzanine: efficiency at every level

The mezzanine structure is designed for heavy loads — up to 700 kg per shelf and dynamic load of intermediate floors at 200 kg/m². On a footprint of 461 m², we created 2300 m² of usable storage area (500% efficiency). The vertical conveyor, integrated into the structure, connects all levels with the packing area, significantly speeding up order processing and minimizing the use of lifting equipment. The central aisle is designed for handling loads up to 1200 kg, ensuring safe operation with warehouse carts on all levels.

Comprehensive storage solution

For this project, Forstor engineers developed an optimal racking system configuration that combines pallet and shelving storage. The placement of double rows and wall-mounted sections allowed for maximum utilization of the available warehouse space while maintaining convenient aisles for material handling equipment.

Warehouse system parameters:

• 11 double rows and wall-mounted row

• Total capacity: 2571 pallet positions

• 284 shelf storage sections

• Shelf storage area: 2260 m²

By combining the mezzanine with automated conveyor and Profi combined racking system, the client received a versatile solution for storing items of various sizes and weights. The implemented solution provides both convenient storage for palletized cargo and efficient placement of small items, significantly optimizing the order picking process and increasing the usable warehouse area fivefold.