Efficient space management in a warehouse is essential for optimising logistical operations and reducing costs. Accurately calculating the maximum storage capacity not only ensures the best use of available space but also enables proper organisation, facilitating the smooth flow of goods and meeting delivery deadlines. This analysis is also crucial for enhancing the operations of logistics-focused companies, where every square metre matters.
In this article, we will break down the essential aspects needed to determine the maximum capacity of a warehouse and the key factors that influence its optimisation.
How is warehouse capacity determined?
Determining the capacity of a warehouse involves analysing various key aspects to establish how space can be utilised efficiently. This includes everything from the physical dimensions of the facility to the storage systems employed.
- Measuring physical dimensions: This is the starting point for calculating available space. The length, width, and total height of the warehouse must be measured.
- Defining operational areas: Not all warehouse space is allocated for storage. Areas must be reserved for aisles, receiving and dispatch zones, and additional operational spaces.
- Selecting the storage system: The type of racks or shelving directly impacts capacity. Systems such as selective racks, drive-in, or push-back racks have specific characteristics that affect space utilisation.
- Evaluating stored products: The dimensions and weight of the products are also crucial. It is important to understand the type of load units (pallets, boxes, containers, etc.) and how they are distributed. This becomes particularly significant in activities such as logistics services for e-commerce, where space optimisation directly impacts the speed of order fulfilment.
Factors to consider when determining storage capacity
A variety of factors influence the storage capacity of a warehouse, and these should be carefully analysed. These factors ensure that space is maximised and logistical operations run smoothly and efficiently.
- Warehouse height: Height is a determining factor, as it dictates how many levels of shelving can be installed. To make the most of height, it is essential to have suitable storage systems and handling equipment that ensures safe operations.
- Aisle design: The width of the aisles has a direct impact on storage density. Narrow aisles allow for more space to be used for storage but require specialised forklifts. Conversely, wider aisles facilitate mobility but reduce the available storage space.
- Inventory turnover: The frequency at which products are moved affects warehouse organisation. Warehouses with high turnover rates require accessible areas, while those with low turnover items can prioritise storage in less convenient locations.
- Product weight: Weight is also an important factor, as shelving and flooring have load limits that must not be exceeded. A prior assessment is necessary to ensure that the structures can support the weight without compromising the safety or integrity of the warehouse. This aspect is critical for efficient planning, particularly when reverse logistics services are integrated into operations.
How to measure the maximum capacity of a warehouse?
Measuring maximum capacity involves calculating the total available volume and then adjusting this figure based on the factors mentioned above. This process ensures that space is used efficiently and that storage solutions are tailored to the specific needs of the warehouse. The steps for measuring maximum capacity are as follows:
- Calculate total gross volume: Multiply the length, width, and height of the warehouse.
Example: A warehouse 50 metres long, 20 metres wide, and 10 metres high has a gross volume of 10,000 m³. - Subtract unusable areas: Deduct space allocated for aisles, loading and unloading zones, offices, and safety areas.
- Apply the occupancy factor: Not all remaining volume can be used. This factor, often 80% in well-organised warehouses, represents the percentage of space that can realistically be used for storing goods.
- Consider the storage system: Adjust capacity according to the characteristics of the racks or shelving system in use.
What is the formula for calculating storage capacity?
The storage capacity can be determined using the following formula:
Storage Capacity = Gross Volume × Occupancy Factor
When working with pallets, you can use this specific formula:
Number of Pallets = Usable Volume ÷ Volume per Pallet
Practical example
A warehouse has a gross volume of 10,000 m³, 20% of which is allocated to aisles and non-usable areas. If the occupancy factor is 80%, the usable volume is:
10,000 × 0.80 = 8,000 m³
If each pallet occupies 2 m³, the total number of pallets that can be stored is:
8,000 ÷ 2 = 4,000 pallets
Maximising the use of space in a warehouse requires a detailed evaluation of its characteristics and operational needs. Factors such as height, aisle design, inventory turnover, and the chosen storage system are crucial for determining capacity. By applying a clear and precise methodology, a warehouse can efficiently meet business demands, improving inventory management and overall operational performance.
