Running out of warehouse space?

Things may happen quickly. One day everything fits, the next day you’re dodging pallets like an obstacle course. It’s a good sign, actually.

But before you start dreaming about a bigger facility, pump the brakes. You can squeeze way more storage out of your current space with the right setup. Let’s talk about how to make every inch count.

Use Vertical Space Like a Pro

Look up. If your warehouse has high ceilings, you might be sitting on wasted space. Instead of spreading inventory across the floor, go vertical.

Here’s how:

• Install taller shelving to stack inventory higher.
• Use pallet racking systems instead of floor stacking.
• Add mezzanines to create a second level for storage or workstations.
• Make sure your forklifts and pallet jacks can handle the extra height. Nobody wants to be that person stuck on a ladder trying to grab a box from the top shelf.

Optimize Aisle Widths

Wide aisles feel nice, but they eat up space. If your aisles are too roomy, consider narrowing them just enough to keep things moving smoothly.

• Standard aisles (10-12 feet) are great for regular forklifts.
• Narrow aisles (5-7 feet) work if you have specialized lift equipment.
• Very narrow aisles (under 5 feet) need turret trucks or reach trucks.
• Don’t overdo it. If workers and equipment struggle to move, you’ve gone too far.

Rethink Your Storage System

Not all inventory should be stored the same way. Adjust your storage system to fit your actual needs.

• Pallet racks for bulky, high-volume items.
• Shelving units for small, frequently picked products.
• Bins and totes for organizing loose inventory.
• Group fast-moving items closer to packing and shipping areas. This cuts down on travel time and keeps orders moving fast.

Clean Up the Clutter

Warehouses collect junk—old pallets, broken equipment, random mystery boxes. Don’t need it? Get rid of it.

• Clear out damaged inventory.
• Recycle broken pallets and unused packaging.
• Set up a returns area to keep unwanted stock from piling up everywhere.
• More space opens up instantly when unnecessary stuff is out of the way.

Cross-Docking for Faster Turnaround

If you move high volumes of inventory, cross-docking might be what you need. Instead of storing everything, receive shipments and send them straight to outbound trucks.

This works best for:

• Fast-moving consumer goods.
• Perishable products.
• High-demand seasonal inventory.
• Less storage time means less space wasted.

Invest in Mobile Storage Racks and Access Equipment

Static shelving wastes flexibility. Mobile storage racks adjust based on demand. If you stack everything up, you’ll also need excellent access equipment.

• Rolling racks let you compact storage when not in use.
• Adjustable shelving adapts to different product sizes.
• Push-back racking allows pallets to slide forward as front ones are removed.
• A little flexibility goes a long way when you’re short on space.

Train Your Team on Warehouse Organization

Even the best setup fails if your team isn’t on board. Train employees to keep things in order.

• Label shelves and storage bins so everything has a home.
• Make sure workers follow proper stacking techniques to prevent wasted space.
• Hold regular clean-up days to reset the warehouse.
• Good organization makes the space feel bigger without adding a single square foot.

Make Safety a Priority

A warehouse with poor organization is a disaster waiting to happen. Safety must always be a focus to avoid costs on damages that would incur if the mess created some accidents.

Workers should always wear protective equipment while in the facility. A well-organized space reduces the possibility of a downtime.

Use Data to Improve Inventory Flow

Guesswork doesn’t cut it. A warehouse management software can track inventory levels and movement.

• Identify slow-moving items that take up space for no reason.
• Optimize reorder points to avoid overstocking.
• Adjust storage based on demand trends.
• A data-driven layout keeps everything efficient.

Rearrange as Needed

Things that worked last year may not work today. Regularly review your warehouse layout so you can adjust based on changing needs.

• Seasonal shifts? Move high-demand products to the front.
• If your business is quickly growing, reassess storage capacity.
• Having workflow issues? Rearrange stations to reduce wasted steps.
• Small changes add up. Keep tweaking until the space works for you.