How Do I Plan a New Warehouse?
Planning a new warehouse is an exciting opportunity for any growing business. Whether you're moving into your first dedicated facility, relocating to a larger premises or expanding your existing operation, the decisions you make at the planning stage can have a lasting impact on how efficiently your warehouse works.
So, how do you plan a new warehouse?
The best approach is to start with your operation rather than the equipment. Think about what you store, how goods move through the building and what your business will need in the future. From there, you can create a practical plan for storage, racking, material handling, work areas and safety.
This guide takes you through the key steps to consider when planning a new warehouse.
1. Understand How Your Warehouse Will Operate
Before choosing racking or ordering equipment, take a step back and look at the bigger picture.
Every warehouse operates differently. Start by understanding:
- What products will you store?
- How much stock will you hold?
- How will goods arrive and leave the building?
- How frequently will stock be picked and moved?
- How many employees will work in the warehouse?
- What equipment will be needed?
- Are there seasonal peaks in demand?
- How do you expect the business to grow?
The answers to these questions should form the foundation of your warehouse plan.
A warehouse designed around the way your business actually operates is likely to be far more efficient than one built around a standard layout.
2. Measure and Understand Your Available Space
The size of the building is only one part of the equation.
When planning your warehouse, consider:
- Total floor area
- Ceiling height
- Doors and loading areas
- Windows and building features
- Columns and structural elements
- Existing offices or facilities
- Access routes
- Available external space
Don't forget to look up. Vertical space can be one of the most valuable assets in a warehouse, particularly when planning storage and racking.
A clear understanding of the building will help you identify where storage, working areas and equipment can realistically be located.
3. Map the Flow of Goods
One of the most important parts of warehouse planning is understanding how goods move from one area to another.
A typical journey might include:
Receiving → Checking → Storage → Picking → Packing → Dispatch
Mapping this journey can help you create a logical layout and avoid unnecessary movement.
Think about where deliveries arrive, where stock needs to be stored and how finished orders leave the building. Keeping related activities close together where practical can help support a smoother workflow.
The goal isn't necessarily to create the shortest route in every situation, but to create a layout that makes sense for your specific operation.
4. Choose the Right Warehouse Storage
Storage is often one of the biggest investments in a new warehouse, so it's important to select solutions around your products and operational requirements.
Depending on what you store, you may need:
- Pallet racking
- Industrial shelving
- Small parts storage
- Bulk storage
- Specialist storage for long or bulky products
- Picking and packing storage
When choosing storage, consider the size and weight of your products, how often they need to be accessed and the equipment used to handle them.
A combination of different storage systems may be more effective than trying to use one solution for everything.
Think About Future Capacity
It's also important not to plan solely around today's stock levels.
If your business is growing, consider whether your warehouse storage can accommodate future expansion or changes in your product range.
5. Plan Your Material Handling Equipment
Once you know where goods will be stored, you need to consider how they will be moved.
The right material handling equipment depends on the loads, distances and frequency of use.
Your warehouse may require:
- Pallet trucks
- Electric pallet trucks
- Stackers
- Trucks and trolleys
- Conveyors
- Lifting equipment
- Specialist handling solutions
The equipment you choose can also influence your warehouse layout. For example, different equipment may require different aisle widths and turning areas.
For the best results, plan your storage and handling equipment together rather than treating them as separate decisions.
6. Create Dedicated Work Areas
Most warehouses need more than storage space.
Think about the areas required for your day-to-day operation, such as:
Goods-In Area
A dedicated space for receiving, checking and preparing incoming deliveries.
Picking Area
A well-organised area for accessing and collecting products for customer orders.
Packing Area
A practical workspace with workbenches, packaging materials and the equipment needed to prepare goods for dispatch.
Dispatch Area
A clearly organised location for completed orders waiting to leave the warehouse.
Returns or Quarantine Areas
Depending on your business, you may need separate areas for returned, damaged or unprocessed goods.
Creating clearly defined zones can help keep the warehouse organised and make each stage of the operation easier to manage.
7. Consider Warehouse Safety From the Beginning
Safety should be part of the warehouse plan from the very start.
When designing your layout, consider how pedestrians, vehicles and material handling equipment will move through the building.
Depending on your operation, you may need to consider:
- Clearly defined pedestrian routes
- Vehicle and equipment movement
- Safety barriers
- Racking and column protection
- Floor markings and signage
- Access equipment
- Emergency access routes
- Appropriate storage for particular materials
The specific requirements will vary depending on your workplace and activities, so it's important to assess the risks relevant to your operation and ensure your plans meet applicable requirements.
Planning safety into the layout from the beginning can be much easier than trying to add it after everything is already installed.
8. Don't Forget Staff Facilities and Workplace Equipment
A warehouse needs to work for the people using it as well as the products being stored.
Depending on your requirements, consider:
- Workbenches
- Seating and workplace furniture
- Cleaning equipment
- Waste and recycling facilities
- Storage for employee equipment
- Welfare and break areas
Creating practical and organised working environments can support the smooth day-to-day running of your operation.
9. Plan for Technology and Future Growth
Warehouses are constantly evolving.
Even if you're not introducing new technology immediately, think about how your business may change over the next few years.
Consider:
- Future increases in stock
- Additional employees
- Changes to product ranges
- New handling equipment
- Automation or technology
- Additional picking and packing requirements
Building flexibility into your warehouse layout can make it easier to adapt without having to completely redesign the facility in the future.
A Simple New Warehouse Planning Checklist
Use this checklist as a starting point when planning your project:
- Understand your current and future operational requirements
- Measure the building and identify key features
- Map the journey of goods through the warehouse
- Plan storage and racking requirements
- Choose suitable material handling equipment
- Allow appropriate space for aisles and equipment movement
- Create dedicated goods-in, picking, packing and dispatch areas
- Consider workplace safety and protection
- Plan work areas and employee facilities
- Allow flexibility for future growth
Every warehouse is different, but working through these areas can help ensure important requirements are considered before equipment is installed.
Common Mistakes When Planning a New Warehouse
Choosing Equipment Before Planning the Layout
It can be tempting to start by selecting racking or handling equipment, but these decisions should be based on the overall operation and available space.
Focusing Only on Storage Capacity
Maximising storage is important, but a warehouse also needs sufficient room for people, equipment and goods to move through the building effectively.
Forgetting About Future Growth
A warehouse that works perfectly today may quickly become restrictive if the business grows. Where possible, build flexibility into the plan.
Treating Safety as an Afterthought
Safety considerations can affect the layout of aisles, storage and working areas. Considering them from the beginning can help create a more practical overall design.
Not Considering the Complete Workflow
A warehouse is a connected operation. Storage, handling, picking, packing and dispatch all need to work together.
Plan Your Warehouse as a Complete Project
The most successful warehouse projects take a complete view of the operation.
Instead of looking at racking, storage and handling equipment individually, consider how each element connects to the next.
At Action Handling, we can help businesses bring together a wide range of equipment for warehouse and factory projects, including:
- Warehouse racking and storage
- Material handling equipment
- Lifting and positioning solutions
- Workbenches and packing equipment
- Access equipment
- Warehouse safety and protection
- Cleaning, waste and recycling equipment
Plan → Design → Supply → Install → Protect
Whether you're starting with an empty warehouse or relocating to a larger facility, taking a coordinated approach can help you create a space designed around the way your business works.
Start Planning Your New Warehouse with Action Handling
If you're asking “How do I plan a new warehouse?”, the first step is understanding what your business needs today and where it is heading tomorrow.
From warehouse storage and racking to material handling, lifting and workplace equipment, Action Handling can help you explore the solutions needed to equip an efficient and practical workspace.
Talk to Us About Your Warehouse Project
Planning a new warehouse, relocating or expanding? Let's discuss your requirements and help you take the next step.
Call: 01279 724989
Email: sales@actionhandling.co.uk
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Plan. Design. Supply. Install. Protect.