STORAGE SOLUTIONS
R
ising property costs, supply chain pressures and the need to hold a wider range of stock mean that many organisations are running out of room long before they run out of business opportunities. For manufacturers operating
from specialist facilities, moving premises is often impractical, expensive and disruptive. As a result, companies are increasingly looking upwards rather than outwards when addressing storage constraints. A recent case study by storage solutions specialist BiGDUG at Sodick Europe illustrates how a strategic approach to warehouse and storage design can unlock significant additional capacity while supporting future business growth.
Sodick Europe, part of the globally recognised Sodick Group, operates from a purpose-built headquarters that serves multiple functions, including sales and marketing operations, storage, training facilities, meeting rooms and a temperature-controlled showroom. Like many manufacturers, the company faced increasing pressure on its available storage space as operational requirements evolved over time. The challenge was not unfamiliar. In many
manufacturing environments, stockholding requirements increase gradually as businesses expand product ranges, hold higher levels of spare parts, or increase inventories to improve resilience against supply chain disruption. The result is often a facility that was originally designed to meet operational needs, but begins to experience capacity constraints several years later.
In the case of Sodick Europe, an existing
two-tier shelving installation had already helped maximise the available footprint; however, continued business growth created demand for additional storage space for parts and consumables. The organisation needed a solution that would increase capacity without disrupting daily operations or requiring costly building extensions. This scenario highlights an increasingly
important trend across industrial and manufacturing sectors. Available floor space is often treated as the primary measure of warehouse capacity, yet the real opportunity frequently lies in making better use of vertical space.
Many facilities continue to underutilise the height within their buildings. Introducing raised access floors, multi-tier shelving systems, and mezzanine-style storage solutions allows businesses to expand storage capacity while maintaining the same physical footprint. For organisations operating from specialist facilities, this approach can deliver significant savings compared with relocation or expansion projects. However, increasing capacity within an
existing structure is rarely as straightforward as installing additional shelving. One of the key challenges in retrofit
storage projects is integration. New storage systems must work seamlessly with existing infrastructure while maintaining safe access
MAXIMISING EXISTING SPACE: WHAT A STORAGE EXPANSION PROJECT REVEALS ABOUT MODERN MANUFACTURING CHALLENGES By Big Dug
Across the manufacturing sector, businesses are facing a common challenge: how to increase storage capacity without increasing their footprint
routes and minimising disruption to normal operations. In established manufacturing environments, this often requires careful planning, detailed surveying and phased installation approaches. At Sodick Europe, an existing two-tier
shelving system was implemented. Achieving this involved more than simply adding extra shelving bays. Sections of the original shelving and cladding needed to be partially dismantled before the new structure could be incorporated. Existing components were then reconfigured and rebuilt in new positions to create a cohesive storage environment. Another important consideration is access
and safety. As facilities introduce additional levels and elevated storage areas, ensuring safe movement of personnel becomes critical. Clear segregation of access routes, controlled entry points and effective safety features must be incorporated from the outset. In Sodick Europe’s expanded storage area,
the installation included a staircase, mesh partitioning and controlled access points to ensure only authorised personnel could access the raised aisle. This approach reflects a wider industry focus on balancing capacity improvements with robust safety standards and operational control. Perhaps the most significant lesson from
the project is that storage challenges should not simply be viewed as space problems. More often, they represent an opportunity to reassess how existing facilities are being used. By analysing workflows, stock profiles and
available building height, manufacturers can often identify untapped capacity within their
26 SEPTEMBER 2026 | FACTORY&HANDLINGSOLUTIONS Big Dug
www.bigdug.co.uk
existing operations. In many cases, relatively targeted interventions can deliver substantial gains without the disruption associated with relocation or major construction work. The outcome at Sodick Europe demonstrates this principle in practice. The storage expansion enabled the company to increase its stores area by approximately 40 per cent, creating additional capacity to support business growth while remaining within its existing facility. As manufacturers continue to face
pressure to improve efficiency, resilience and responsiveness, warehouse optimisation is likely to remain a priority. The organisations that succeed will be those that view storage not simply as a necessity, but as a strategic asset capable of supporting long-term operational performance.
By making smarter use of vertical space and designing systems that can adapt as requirements change, businesses can transform storage constraints into opportunities for growth.
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