Client Overview
A mid-sized packaging and commercial printing company in Southern China operates two production lines for corrugated boxes, carton boards, and laminated packaging. With daily raw material intake exceeding 30 tons, the 4,000㎡ warehouse stores heavy paper rolls, stacked cardboard pallets, and finished bulk packaging—all demanding load-bearing capacity that the existing light-duty shelving could no longer provide.
The Challenge
The original
racking was never built for current loads:
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Overloaded beyond design limits: Beams rated for 300–500 kg routinely held 800+ kg pallet loads. Visible beam deformation and bowed uprights triggered a high-risk safety flag in the internal audit.
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Unstable heavy roll storage: Paper rolls (600–1,200 kg each) sat on makeshift timber supports over standard beams, causing deflection and roll shift during forklift placement.
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Floor congestion: Bulk cardboard pallets (1,000+ kg each) were stacked three-high directly on the floor, blocking aisles and fire exits.
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Wasted vertical space: With an 8.0 m clear height, the light-duty system topped out at 4.5 m—leaving 3.5 m of dead airspace.
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Material waste: Bottom-of-stack cardboard compression and roll edge crush drove ¥12,000/month in handling damage.
Shibang's Tailored Solution
Shibang conducted a full structural assessment—load mapping, seismic evaluation, and traffic analysis—before engineering a heavy-duty system built for weight, safety, and accessibility:
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Reinforced Upright System: Box-section uprights (120×95×2.5 mm) rated up to 21,000 kg per frame with seismic-zone bracing.
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High-Capacity Beams: 140×50×1.8 mm box beams with safety-lock connectors, 2,000 kg per pair—over double the old system's rating.
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Roll Support Channels: 600 mm spaced channels with central brace, each position supporting 1,500 kg with zero measurable deflection.
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Five-Level Vertical Layout: Extended to 7.2 m working height (up from three levels), delivering a 45% increase in storage positions within the same footprint.
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Safety Package: Anti-collapse mesh on rear faces, polyethylene forklift impact guards on every upright, aisle-end double-rail barriers, and load capacity signage on every beam level.
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Certified Installation: 10-day professional install with full torque verification; third-party structural engineer inspection and certification upon completion.
Results & Impact
✅ Zero structural issues—all components operating within rated limits
✅ 45% increase in effective storage capacity
✅ 60% reduction in handling-related material damage (¥12,000 → ¥4,800/month)
✅ Zero overloading incidents post-installation
✅ Full fire-safety clearance compliance—all exits and lanes unobstructed
✅ Third-party safety certification passed on first inspection
Annualized savings: ~$24,000 USD | Payback period: under 20 months
"Safety was our #1 concern, and Shibang treated it that way from day one. The structural calculations, the certified installation, the safety accessories—every detail was covered. We can finally store heavy loads without holding our breath."
— Operations Manager, Packaging & Printing Co., Ltd.
Why Choose Shibang Racking?
18+ years delivering customized, durable, scalable racking across textiles, apparel, printing, automotive, and e-commerce. From light-duty shelving to heavy-duty industrial systems, we engineer around your load requirements and safety standards.
