IBCs play a critical role in the storage and movement of liquids, powders and hazardous materials across the chemical, pharmaceutical, coatings, food and manufacturing sectors. However, while IBCs are highly effective as transport vessels, they often create significant challenges inside the warehouse. Many facilities still rely on traditional racking or floor stacking, which can lead … Continued
What Happens If Warehouse Automation Stops? It’s one of the first questions we are asked when discussing warehouse automation projects. “What happens if the system stops?” It’s a completely valid concern. For many operations directors and warehouse managers, the idea of an automated pallet storage system stopping unexpectedly can feel like introducing risk into an … Continued
We are incredibly proud to be celebrating our 30th year in business. Reaching this milestone gives us a real opportunity to look back on how far we have come since we were established on 4th March 1996. When we started, we had a simple belief. Storage and handling systems could, and should, perform better. That … Continued
Introduction to Automated Racking Automated Racking Solutions can deliver a number of significant benefits; however, the one thing that gets people turned on to the concept is how much additional capacity it can deliver. Once the potential to increase capacity, often exponentially, is established, the supplementary benefits such as improved throughput, improved safety, reduced operating … Continued
High-density automated storage solutions for secure, safety-critical and regulated defence environments. Defence organisations face increasing pressure to improve storage density, strengthen operational resilience, protect critical inventory and modernise infrastructure without compromising safety, compliance or security. Thistle Systems supports secure, safety-critical and regulated storage environments with intelligent automated storage solutions engineered for complex defence applications. Built … Continued
A high-growth 3PL ecommerce fulfilment operation needed to fundamentally change how it handled storage, picking, and replenishment. Manual processes were labour-intensive, difficult to scale, and increasingly unable to support rising order volumes and service level expectations. To address these challenges, the business implemented a Brightpick robotic solution to automate storage, retrieval, putaway, and order picking … Continued
Chemical and pharmaceutical warehousing in the UK operates under rigorous regulatory and safety expectations. ATEX zoning, COMAH obligations, segregation requirements, validation protocols, audit trails, and, alongside that, the commercial pressure to increase capacity, improve throughput, and reduce operating costs. Thistle Systems is one of the UK’s leading warehouse automation integrators, delivering advanced warehouse automation for … Continued
Welcome to the third part of our series on the myths associated with Automated Racking and Automated Storage Solutions. We have already discussed the myths surrounding the costs of automated storage solutions and automated storage being seen to be only suitable for large warehouses and large cold stores. One of the biggest concerns we get … Continued
The growing interest in automated storage has accelerated rapidly over the last 12 months. However, too many companies have either quickly dismissed or not even considered the concept, believing the myth that Automated Racking is Too Expensive. At Thistle Systems, we have been developing a range of semi-automated and automated storage solutions for the last … Continued
Do You Have A Capacity Issue or a Utilisation Issue in Your Warehouse? Storage capacity is often seen as the primary focus for many companies as they look at ways to improve their operations. However, it can be quite misleading when it comes to operational effectiveness and efficiency. The total storage capacity of a warehouse … Continued
AUTOMATED RACKING MYTH BUSTING NUMBER 1: Most people accept and understand the general concept of automated racking systems and the significant operational benefits it can deliver.However, there is a general misconception that automated racking and storage are only suitable for larger warehouses and cold stores. The truth is the viable size of automated storage isn’t … Continued
A quick analysis will show that many companies find approximately 80% of their sales are generated by approximately 20% of their SKUs. Now, whilst this may be beneficial for the sales teams, it can cause a number of challenges in the warehouse to achieve the perfect balance of space and picking speed. Some warehouse managers … Continued
Automated Cold Storage is one of the hot topics in the food and drink sector as companies look to improve efficiency and reduce costs in their cold store warehouses. The increase in energy and running costs is presenting operators and food companies with complex challenges which may be restricting growth, profitability, and service. To remain … Continued
The demands being placed on finished goods and dry goods warehouses in today’s market have changed dramatically from those they faced 10 or 20 years ago. Warehouse Managers are facing the challenge of a seemingly never-ending increase in SKUs, growing capacity requirements and an increasingly demanding marketplace who want your warehouse to be more responsive … Continued
The massive changes in the economy and the significant developments in automation, robots and technology is challenging businesses to think differently and effectively to achieve a step change in their operations. Whilst senior managers and boards of directors are looking at incremental changes to improve capacity through improved design and dynamic systems such as push … Continued
The construction and operating costs of a cold storage warehouse (or cold room) are such that the need to Max the Cube® by maximise storage capacity in the minimum floor area with a cold store racking system, is absolutely essential. With technology moving on at a pace, the ability to consider dynamic and semi-automated storage … Continued
The spiralling energy costs are forcing businesses to take decisive action on their warehouse operations which could have a massive impact on the industry. With energy typically accounting for 15% of overall warehouse costs and reports of up to 400% increases in the coming months, many businesses are now looking at every opportunity to consolidate … Continued
If you look around your warehouse and seeing lots of half or part pallets on your standard pallet racking or you buy product by the pallet layer, you will absolutely want to read this Depending on the percentage of part pallets you have and the height of your warehouse, you may be able to reduce … Continued
The demands being placed on distribution centres are at an all-time high as customers demand even shorter lead times, with many companies being forced to offer next day or even same day delivery service just to compete. Much of this is being driven by the continued growth in internet sales which reached an all-time high … Continued
The Push back racking system is probably one of the most flexible dynamic pallet racking solutions on the market today. Not only can it deliver high-density storage solutions, but our Maxi Cube Push Back Racking can also dramatically improve picking speeds and space utilisation, which can significantly reduce operational costs. Below, we explain a few … Continued
Mezzanine floors are often seen as being one of the most effective solutions for creating additional floor space without having to extend or rent new premises. However, the term mezzanine floor is often mis-used and as a result, we see companies ending up paying too much for an over-engineered solution that they don’t really need. … Continued
As more and more companies look to Max the Cube® by maximising capacity and improving the space utilisation of every inch of the warehouse, the demand for Thistle Systems Maxicube Shuttle Racking, or radio shuttle racking as it is sometimes referred to, is increasing dramatically. What Is Shuttle Racking Shuttle racking uses a combination of … Continued
Have you considered how much money you spend every year stocking and retrieving pallets from your warehouse? The cost of forklift trucks and drivers is a sizable element of any warehouse operation but is often overlooked when deciding on the optimum racking solution. And whilst drive-in racking is seen by many companies as an excellent … Continued
The exponential growth of SKUs is a challenge facing many warehouse managers and none more so than those operating within the wholesale market. The challenge is further compounded by customers looking for greater flexibility in ordering, resulting in more mixed pallets being created and, as a result, more broken/split/half pallets needing to be stored. The … Continued
One of the most common questions we get asked is, “Can You Explain How Much Mezzanine Flooring Costs?” That’s because mezzanine floors are seen as one of the most effective solutions for creating additional floor space without having to extend or rent new premises – check out a selection of our mezzanine floor case studies. … Continued
The challenge in warehouse automation is the ability of the software system to get the right pallet to the right place at the right time to enable the despatch area to meet their KPIs. Get this right and the potential Return on Investment can be enormous, however doing so requires a synchronised co-ordination of the … Continued
Drive-in racking is a firm favourite when it comes to high-density racking solutions, especially in distribution centres and cold stores where maximising capacity is a key driver. However, like every industrial racking system, drive-in pallet racking isn’t perfect and doesn’t suit every project. So whilst drive-in racking may appear to be a cheaper investment, the … Continued
Block stacking in your warehouse is generally perceived as the cheapest approach to storing your products, and you would be forgiven for agreeing. Yes, it requires zero investment in racking systems, and the only piece of equipment needed is a forklift truck. However, many smart companies focused on safety are recognising what is perceived … Continued
The impact of the COVID-19 pandemic has only accelerated the anticipated future growth and demands on fulfilment centres which have been driven by the dramatic growth of internet sales. This has resulted in a growing interest in automated storage solutions and goods to person systems which can deliver major improvements in efficiency and costs savings … Continued
Most people tend to focus on the increased capacity when they discuss shuttle racking benefits as opposed to the incredible cost savings the solution can deliver. It’s understandable really, as shuttle racking can deliver a dramatic increase in storage capacity which is often the main driver of the project, however, when clients see the additional … Continued
Mobile office shelving and Industrial Mobile shelving systems can deliver enormous space saving solutions for virtually any environment. However, to ensure these solutions continue to operate smoothly and effectively, they must be regularly inspected and maintained. In fact, the Health and Safety Executive’s PUWER regulations, recommend your mobile shelving system is inspected by an expert … Continued
The challenge in any warehouse is to maximise capacity in the minimum floor space whilst optimising accessibility to ensure efficiency is never compromised. And whilst many companies focus on their pallet storage, one of the most challenging areas of business, particularly for Engineering and Automotive businesses, is how to store small parts. Typically, small parts … Continued
Block stacking has been a favourite method of storing pallets and IBCs in warehouses across the UK for two main reasons: It requires no capital expenditure That’s the way we have always done it However, with moves by the HSE to minimise the heights which companies are block stacking pallets, there is a growing acceptance … Continued
Block stacking may appear to be a cheap and effective storage solution for many companies whether it’s during periods of growth or simply through tradition. Most people understand that block stacking isn’t always the most effective or efficient way to store pallets but, in many circumstances, it does what is required. However, that appears to … Continued
If you are currently using an external storage provider to store pallets or are looking at extending your warehouse, shuttle racking presents a real opportunity to deliver significant cost savings through better space utilisation and improvements to operational efficiencies. One company even recognised the potential to save over £1million per year by using shuttle racking … Continued
We have seen an increasing number of clients asking us about PRRS Racking Safety Training with regards to Person Responsible for Racking Safety which can only mean that this is something that the HSE are now focusing on more. Check out our PRRS Rack Safety course outline In response to this, we have pulled together the below … Continued
The traditional approach to managing your own finished goods warehouse is fairly common. The warehouse stores a combination of full and broken pallets. These may be block stacked with the broken pallet at the front or in different types of racking depending on the number of SKUs. The process of preparing loads ready for despatch … Continued
The Max the Cube® Shuttle Racking system, or Shuttle Storage System as they are sometimes referred to, allows you to maximise the full potential of your warehouse by dramatically increasing capacity, reducing operating costs and improving throughput. By using a combination of high-density racking and a semi-automated shuttle, the solution enables you to truly maximise … Continued
Adjustable Pallet Racking (APR) pallet racking continues to be the most popular warehouse racking solution used in the UK – possibly because its seen as the easiest to design and the cheapest racking to buy. However, from our experience and regular enquiries from companies across the UK, the storage solution can often be one of … Continued
Mezzanine Floors is a general term for a raised steel structure to create an additional level of flooring which can be used for a multitude of uses from storage and production to office and retail. Mezzanines provide an excellent method of utilising the available height within a facility to increase floor space and avoid the … Continued
Depending on the pallet storage rates, external warehouse storage can often be a highly cost-effective strategy for minimising your overheads or for providing essential additional facilities, such as during peak seasonal periods or during a growth phase. However, if these pallet storage prices become a regular monthly cost, it may be time to consider the … Continued
Dynamic Pallet Racking is the term used to describe storage solutions which use mechanical or gravitational forces to move pallets within the racking system. These include push back racking, pallet live racking, mobile pallet racking, picking tunnels and radio shuttle racking. These Dynamic Pallet Racking solutions are transforming traditional warehouse storage by enabling companies to … Continued
Mobile Pallet Racking (MOVO) has the ability to deliver a high density storage capacity whilst providing 100% picking access to every pallet position, making it a firm favourite for companies looking to maximise space utilisation, particularly in areas such as cold stores. The system uses conventional pallet racking which is located onto mobile bases on a … Continued
Blame Tim Wood – He is the Reason You Are Losing Money If you are looking for the reason why your operations just aren’t performing at the level you are after – you need to get rid of TIM WOOD. Every organisation has a TIM WOOD but before you go calling HR to find out … Continued
After studying thousands of warehouse operations in its Max the Cube approach and analysing the impact of racking solutions, Thistle Systems has uncovered one of the biggest warehouse operating costs – and it’s not the racking. And it doesn’t matter whether you are spending a few hundred pounds or hundreds of thousands of pounds on … Continued
The traditional approach to warehouse design, whether it’s a new building or an extension to an existing facility, is to build the warehouse to the sizes specified by the architect or consultant based on a general rule of thumb. Once these are agreed, the client then looks at bringing in a racking solutions company and … Continued
Have you considered how much money you spend every year stocking and retrieving pallets from you warehouse? The cost of fork lift trucks and drivers is a sizable element of any warehouse operation but is often overlooked when it comes to deciding on the optimum racking solution. It was certainly the case when we spoke … Continued
IBCs are a popular and highly efficient storage solution, especially in sectors such as chemicals, engineering and food and drink, however IBC storage systems can be problematic. IBC storage is not without its challenges both from a space utilisation AND a health and safety point of view. Whilst they are cube shaped which allows them to be … Continued
The concept of push back racking is very easy to understand, however the full benefits that pushback racking offers are often overlooked. For more examples of how Push Back Racking has helped companies maximise their capacity, click here or see below for an outline of the benefits. The Benefits of Push Back Racking As you … Continued
When was the last time you evaluated your true Warehouse Racking Costs? What factors did you take into consideration? Thistle Systems has compiled data from over 3000 installations and projects over the last 10 years in an attempt to identify how people measure their racking systems and what they believed were the costs involved in … Continued
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© 2026 Thistle Systems
