How to Make Better Use of Warehouse Space with the Right Storage Systems
A warehouse can feel full long before every square foot is being used well. Materials may be stacked on the floor, employees may have to move one item to reach another, or valuable production space may be occupied by storage that no longer fits the process.
Better warehouse storage starts with what you need to store, how often you need it, and how materials move through the facility.
The answer is not always more shelving.
Small parts, sheet metal, long stock, and bulky equipment each need different storage and access arrangements.
Here is how to evaluate your space and determine which industrial storage systems are worth considering.
1. Identify What Is Taking Up Space
Before choosing new racks or cabinets, look at the current storage layout.
Where are materials accumulating? What takes the longest to find? What frequently has to be moved out of the way?
Common signs that storage needs attention include:
Parts or raw materials kept on the floor
Frequently used items stored far from the point of use
Mixed inventory that is difficult to identify
Oversized loads occupying areas intended for smaller items
Aisles or equipment access becoming obstructed
Available vertical space that is not being used
The goal is to understand whether the problem is storage capacity, material access, or the flow of work. Often, it is a combination of all three.
You should also separate regularly used stock from items that are rarely needed. Material retrieved every hour should not necessarily be stored in the same way as material accessed once a month.
2. Match the Storage System to the Material
Different materials create different storage problems. Start by grouping inventory by size, weight, handling method, and how often it needs to be retrieved.
What you need to store | Storage system to evaluate |
Tools, components, and small parts | Modular drawer cabinets, shelving, and workstations |
Sheet metal, plates, or dies | Roll-out sheet racks and specialized sliding storage |
Long bars, pipe, or structural stock | Cantilever racking or suitable roll-out systems |
Inventory that can use an upper level | An engineered industrial mezzanine |
Materials needing separated access or controlled areas | Storage partitions and designated equipment zones |
These are starting points, not interchangeable solutions. Final selection depends on load capacity, material dimensions, available space, and the equipment used to retrieve each item.
A storage system only saves useful space if people can still retrieve materials efficiently.
3. Use Modular Cabinets for Tools and Small Parts
Small parts and tools can occupy more floor space than expected when they are stored across multiple shelves, workbenches, and open containers.
For these applications, modular drawer cabinets and organized workstations may help consolidate inventory while keeping it accessible.
Our distribution partner Rousseau, manufactures industrial storage systems that include heavy-duty drawer cabinets, shelving, and configurable workstations.
Drawer layouts can be selected around the sizes and quantities of the items being stored. Dividers, bins, and compartment options help separate parts that otherwise become mixed together.
These systems can be particularly useful when:
Assemblers or maintenance technicians need frequent access to tools
Small components must be organized by size or part number
Storage needs to sit close to the workstation
A facility wants a repeatable storage layout across multiple departments
When selecting cabinets, check drawer capacity, overall dimensions, clearance for fully opened drawers, and the way the cabinet will be stocked.
4. Consider Roll-Out Racks for Sheets and Heavy Materials
Sheet metal and other heavy stock can be awkward to store and retrieve, especially when multiple sizes or materials are stacked together.
If workers regularly have to move one sheet or load to reach another, the arrangement may be creating unnecessary handling.
Roll Out Racks manufactures storage equipment for applications such as sheet metal, plates, and long materials. Its systems include roll-out sheet racks, sheet towers, and cantilever-style options.
A roll-out rack can make individual storage levels accessible without requiring employees to rearrange an entire stack.
For example, a sheet rack with sliding drawers may be worth evaluating when a fabrication shop stores multiple sheet sizes that need to be loaded or retrieved with handling equipment.
Before choosing one, identify:
The size, weight, and thickness of the material
Whether stock is stored individually or in bundles
How material will be loaded and removed
The equipment needed to access the rack
Clearance required when a drawer is extended
The number of separate storage levels needed
The right question is not just how much material a rack can hold, but how easily the next piece can be reached.
5. Make Better Use of Vertical Space With Mezzanines and Cantilever Racking
Sometimes the biggest opportunity is above the warehouse floor.
If a facility has sufficient overhead clearance, a properly designed mezzanine may provide an additional level for suitable storage or work activities without expanding the building footprint.
Cogan offers industrial mezzanines and other warehouse products, including cantilever racking, partitions, guardrails, and rack-protection equipment.
A mezzanine is not simply an extra shelf. The intended use, loads, columns, access, building conditions, and applicable requirements all need to be evaluated as part of the project.
Cogan cantilever racking addresses a different problem. Its open-front configuration can be useful for long items such as pipe, tubing, and structural materials that do not fit conventional shelf layouts.
These systems solve different needs:
Industrial mezzanines: Evaluate when additional usable floor area is needed and the building can accommodate an engineered upper level.
Cantilever racking: Evaluate when the facility handles long, bulky, or irregular stock that needs suitable support and front access.
6. Plan the Layout Around Material Flow
Storage density matters, but maximizing the number of racks is not the same as improving the warehouse.
A layout should account for how material arrives, where it is stored, how it is picked, and where it goes next.
Ask:
Which materials need to be closest to production?
What equipment moves materials between storage and work areas?
How frequently will each storage location be accessed?
Will forklifts, pallet jacks, or overhead lifting equipment need access?
Are aisles, exits, doors, and maintenance areas kept clear?
Could the proposed layout make future changes more difficult?
A highly compact storage system can become counterproductive if it creates longer travel paths or prevents material-handling equipment from reaching inventory.
The best storage layout is not always the one that holds the most material. It is the one that supports how the facility actually works.
7. Check Capacity and Installation Requirements
Industrial storage must be selected around the loads and conditions it will experience.
Before finalizing equipment, consider maximum material weight, how loads are distributed, the floor or supporting structure, required clearances, and the proposed loading method.
Mezzanine projects may require structural engineering and coordination with building and fire requirements. Racking layouts need to account for safe loading, aisle access, and material-handling equipment.
The requirements vary by facility and equipment type. A cabinet near an assembly station is a different project from a mezzanine carrying stored materials above an active production area.
Confirm the specific equipment ratings and installation requirements before approving a layout.
8. What to Have Ready Before Discussing Warehouse Storage
You do not need to have a complete warehouse redesign prepared before contacting a supplier.
The following information is useful for an initial conversation:
Description of the material being stored
Typical and maximum weight per item or bundle
Dimensions of the largest and smallest loads
Approximate inventory quantities
How often the material is accessed
Current storage challenges
Available floor dimensions and ceiling height
Forklift, pallet jack, or other handling-equipment requirements
Photographs or a simple facility layout
These details help narrow the storage options and identify what needs further engineering review.
Frequently Asked Questions
What is the best way to increase warehouse storage space?
Start by identifying unused vertical space, poorly organized inventory, and areas where materials block access. The right improvement may involve cabinets, specialty racks, a different layout, or an engineered mezzanine.
When should a facility use roll-out racks?
Roll-out racks may be useful for sheet metal and other heavy materials when stacked storage makes individual loads difficult to retrieve. The appropriate design depends on material dimensions, weight, and handling equipment.
What is the difference between shelving and cantilever racking?
Conventional shelving typically supports items between uprights or on shelves. Cantilever racking uses projecting arms and an open front, making it a possible option for long stock such as pipe, tubing, and bar material.
Does every warehouse benefit from a mezzanine?
No. A mezzanine only makes sense if additional upper-level area meets a real operational need and the building, loads, access, and applicable requirements can support the design.
Planning a Warehouse Storage Improvement?
At Norbac, we help manufacturers evaluate industrial storage and material-handling requirements and identify solutions that fit their facility.
Whether you need better organization for tools and parts, easier access to heavy stock, or a way to use available building space more effectively, start by telling us what you are storing and how it needs to move.
We can help you review the options and determine the next step.
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