Tailored Racking for Apparel: A Distribution Center Upgrade Case

Client Overview

A domestic mid-sized apparel enterprise integrates design, production, and omni-channel sales. Its 3,000㎡ distribution center handles 2,000+ SKUs, including hanging garments, folded apparel cartons, and footwear boxes. With rising order volumes and faster collection turnover, the existing storage setup could no longer support daily outbound operations efficiently.

The Challenge

The original uniform shelving failed to accommodate diverse apparel formats:

Hanging coats and dresses were folded on shelves, causing wrinkles and extra ironing work before dispatch.

Footwear boxes and apparel cartons were stacked deep, forcing staff to move multiple boxes just to reach one at the back.

No clear storage zones — pickers spent excessive time searching for items, dragging down overall efficiency.

Limited vertical use left upper warehouse space underutilized.

Seasonal order surges led to floor stacking that blocked aisles and increased the risk of product damage.

Shibang's Tailored Solution

After analyzing SKU profiles, order velocity, and picking workflows, Shibang delivered a composite racking system tailored for apparel storage:

Garment Hanging Racking: Cantilever hanging rails with smooth-glide hooks allow dresses, coats, and suits to move on hanger from receiving to dispatch, eliminating creases and rework.

Multi-Tier Selective Racking: Five-level shelving with shortened beam spans prevents carton sagging. Adjustable shelf heights adapt to varying carton sizes across seasons.

Footwear Pick Shelving: Inclined shelves with removable dividers keep shoeboxes visible and accessible, reducing search time to a minimum.

Zoned Layout: High-velocity items placed in forward-pick zones near packing stations; slower-moving stock stored in rear areas. Pick paths optimized to cut travel distance.

WMS-Ready Labeling: Structured location codes at every bay and shelf level enable accurate inventory tracking and faster order picking.

Results & Impact

✅ 55% faster order picking speed

✅ Zero garment re-steaming required post-installation

✅ 32% reduction in warehouse labor hours

✅ 38% increase in effective storage capacity within the same footprint

✅ Seamless WMS integration with 99.3% pick accuracy

"The new racking system fits how we actually work. Hanging garments stay wrinkle-free, cartons are easy to reach, and our team spends less time searching and more time shipping."

— Warehouse Manager, Apparel Enterprise

Why Choose Shibang Racking?

18+ years delivering customized, durable, scalable racking across textiles, apparel, printing, automotive, and e-commerce. We engineer the system around your product — not the other way around.