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
When it comes to increasing capacity in your warehouse, it may seem that the easy option is to get more of the same type of racking and dedicate more space or get a new warehouse. But that isn’t always the best option, as one of the UK’s largest drinks manufacturers discovered. The company had originally … Continued
One of the biggest challenges for many companies is developing a cost effective storage facility which provides them with the flexibility to store all of their products whilst maximising the potential capacity. This is particularly an issue for companies which receive a variety of pallet types and individual products to be stored in a single … Continued
Looking for the best warehouse racking system to maximise capacity and improve the performance of your warehouse? It’s a question that we are often asked but unfortunately, there isn’t one simple answer. The footprint and height of each warehouse may be slightly different. The pallet size may vary. The products being stored are likely to be … Continued
The days of simply carrying out a formal racking inspection once or twice or year just to meet your HSE obligations are now seen as a reactive approach to warehouse management. Therefore, Thistle Systems has developed a practical hands-on training programme for storage safety awareness, to provide your warehouse operators with the basic knowledge of safe … Continued
The very mention of an HSE Inspector can strike fear into the heart of even the toughest, most safety- orientated Warehouse or Production Manager. Add in the threat of Intervention Fees of £129 per hour for any “material breach of HSE regulations” and it’s easy to see why they are probably not the most welcome … Continued
Max the Cube® is a unique approach which shows companies how they can maximise capacity and productivity within their warehouse, interiors and production facilities whilst dramatically reducing operating costs. We are on a crusade to help companies to capitalise on the huge potential that exists within every organisation to maximise every inch of storage space, … Continued
Max the Cube® is NOT for the Average Company If there is one thing we have learned from the last few years, it’s the fact that simply being average is effectively guaranteeing failure. The seismic shift in the way people now have access to a world of information prior to buying products and services means … Continued
As part of the initial process for developing Max the Cube®, we carried out extensive research to understand the challenges being faced by the key sectors in our economy. We found that companies were not maximising the capacity or the utilisation of their warehouse. This meant they were facing unnecessary costs such as external storage, … Continued
Thistle Systems has seen its Max the Cube® approach successfully achieve certification to the recently updated and internationally recognised ISO 9001:2015 quality standard. This certification demonstrates that the unique approach is more than simply a powerful concept, but is supported by a high quality management system which covers the design and project management of storage systems … Continued
The recent racking collapse in a cheese warehouse in Shropshire has highlighted the need for companies to carry out regular rack inspections in addition to the annual inspection which companies are legally required to do. The incident saw the entire racking system, which was up to 18 metres high and contained thousands of 20kg boxes … Continued
Thistle Systems’ Max the Cube® approach has been recognised as the perfect vehicle for companies looking to implement the 5S methodology within their warehouse storage and production facilities. Check out our ultra high density storage solutions – ideal for small components The Max the Cube® approach draws upon the key philosophies promoted by the 5S … Continued
Despite being in business for 20 years, its only in the last 4 where we have truly been able to tell people what it is that we can actually do for their business in a manner they can instantly relate to. This came when we developed our Max the Cube® approach which effectively harnessed the … Continued
As more companies look for ways in which they can make savings, Thistle Systems Group, one of the UK’s leading suppliers of racking has urged all companies to think carefully about the potential dangers of purchasing and installing used racking systems. With offers of amazing savings from online retailers and auction sites such as ebay … Continued
Dangerous Racking is a key issue in any warehouse as it may present a major health and safety risk. No matter how much action you take to protect damage to your racking system or how much training you provide your forklift drivers, you cannot account for wear and tear or of course human error. The truth … Continued
It’s all too easy to put off carrying out racking inspections or indeed the costs of rectifying problem – however the true cost of racking which is unsafe could be far greater. Clearly the cost of replacing an upright or a section of racking is a fraction of the cost of replacing the entire racking system, however … Continued
There is incredible video footage shows the devastating impact poorly constructed racking can have on a warehouse. The most worrying aspect is how little contact there is between the forklift and the horizontal beam which causes virtually all of the racking to collapse. It’s almost impossible to determine the real cause of the problem from … Continued
Did you know that by moving pallet racking beams you could be reducing your load capacity by as much as 80%? During a recent site survey we identified that the bottom brace of a system we had installed had been removed to allow other non-palletised items to be stored. The client was horrified to find … Continued
We are always discussing the benefits of rack protection with our clients and how they can save money in the long run by a comparatively small investment. Last week I visited a new client who was looking for assistance with some rack repair work after a forklift truck had crashed into his racking system. The … Continued
© 2026 Thistle Systems
© 2026 Thistle Systems
