Project: Heavy-Duty Selective Racking System
Date: April.2026
Location: Ecuador
Project Overview
Customer is a 3PL Warehousing Company for a wide range of transport items, including cartons, boxes, bulk item pallets and package item for heavy duty parts.
The facility handles a wide variety of products, including consumer goods, packaged items, spare parts, and bulk cartons. Rapid SKU growth and increasing order complexity created urgent demand for a flexible, high-load, and space-efficient storage system.
HEDA Shelves delivered a heavy-duty selective pallet racking system rated at 2000 kg per layer, designed to support diverse inventory types while improving picking efficiency and warehouse organization.
Client Challenge
As SKU variety increased, the warehouse faced several operational constraints:
- Rapid SKU expansion leading to disorganized storage zones
- Inefficient use of warehouse height due to partial pallet stacking
- Increased picking errors in mixed-product zones
- Limited scalability of existing shelving systems
- Need for safe handling of both light cartons and heavy palletized goods
The client required a universal racking system that could support multiple product categories while maintaining high load capacity and operational flexibility.
How We Work
HEDA Shelves designed and supplied a selective heavy-duty pallet racking system optimized for multi-SKU operations, featuring:
Load capacity: 2000 kg per layer
- Flexible beam level adjustability for different SKU sizes
- Direct pallet access for fast picking and replenishment
- High-density vertical storage utilization
- Forklift-compatible aisle design for efficient traffic flow
The system was engineered to balance storage density and SKU accessibility, a key requirement for multi-category warehouses.
Design & Engineering Approach
1. SKU-Based Storage Planning
The warehouse layout was designed after analyzing SKU velocity, pallet dimensions, and inventory turnover patterns. Fast-moving goods were positioned for easy access, while slower-moving SKUs were stored in higher rack levels.
2. Structural Strength & Adaptability
To support mixed inventory types, the racking system included:
- Reinforced upright frames for high load stability
- Adjustable beam levels for different pallet heights
- Uniform load distribution design rated at 2000 kg per layer
- Industrial-grade powder coating for durability in daily forklift operations
3. Space Optimization Strategy
The system fully utilized vertical warehouse space, replacing inefficient floor stacking and random shelving with a structured grid-based storage model.
Implementation Process
Phase 1: Warehouse Layout Design
A customized CAD layout was developed to optimize aisle width, rack height, and SKU zoning strategy.
Phase 2: Production & Quality Assurance
All racking components were manufactured under strict load-bearing and safety standards to ensure stability under mixed SKU conditions.
Phase 3: On-Site Installation Support
HEDA provided installation guidance to ensure precise alignment, safe anchoring, and optimal forklift accessibility.
Results & Impact
After deployment, the warehouse achieved measurable operational improvements:
- Significantly improved SKU organization with structured zoning
- Higher storage density through full vertical space utilization
- Faster picking efficiency due to direct access to palletized goods
- Reduced picking errors through clear SKU separation
- Scalable warehouse structure ready for future SKU expansion
The facility transitioned from a fragmented storage system into a highly organized multi-SKU logistics warehouse.