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Client: A leading pet supplies supply chain enterprise in East China.
Pain Points: Managing over 8,000 SKUs—including 15kg bulk cat litter, canned wet food, and irregularly shaped pet furniture—proved challenging with the existing mezzanine racking. Key issues included:
Structural Stress: Overloaded bottom shelves in the cat litter zone caused permanent deformation and collapse risks.
Inefficient Picking: Mixed storage of lightweight treats and heavy bulk litter forced pickers to navigate multiple floors, creating chaotic travel paths.
Compliance Risks: Wooden shelves absorbed moisture and fostered mold, threatening SQF (Safe Quality Food) certification.
Zoned Load Capacity: Heavy-duty zones (litter/food) required ≥800kg per level; general merchandise zones required ≥300kg per level.
Operational Efficiency: Support both full-pallet storage and piece-picking workflows while minimizing travel distance.
Hygiene Compliance: All-steel construction with easy-to-sanitize surfaces meeting pet food contact safety standards.
Implementation of a Heavy-Duty Selective Racking System with Steel Decking:
Structural Configuration: Main racks at 6m height (4 levels) featuring 90×70mm columns. Heavy zones utilized reinforced beams (1,000kg/level), while general zones used P-beams with steel decking (400kg/level).
Optimized Layout: Segregated "Bulk Zone" (1,200 pallet positions for litter/food) with narrow aisles (2.8m) and a "Pick Zone" (2,000 picking positions for treats/supplies) utilizing carton flow racks for replenishment.
Sanitation Design: Full electrostatic powder coating (light grey) with folded edges on decking to eliminate dust traps. Raised 150mm off the floor for easy cleaning.
Safety Features: Column guards, pallet backstops, and LED aisle lighting installed throughout.
Compliance & Safety: Passed SQF audits with zero shelf deformation and a 100% reduction in safety incidents.
Efficiency Gains: Picking paths shortened by 40%. Daily order processing capacity surged from 3,000 to 6,500 orders, boosting picker productivity by 80%.
Reduced Waste: Steel decking prevented moisture damage, reducing spoilage rates for pet food from 2.5% to 0.3%.
The solution moved beyond generic racking to address the specific "mixed-weight and high-hygiene" nature of the pet industry. While steel decking increased initial costs by 20% compared to wood, it eliminated mold risks, extended the racking lifespan to over 15 years, and delivered a projected ROI within two years.
