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
IBCs are a popular and highly efficient storage solution, especially in sectors such as chemicals, engineering and food and drink, however, IBC storage is not without its challenges, both from a space utilisation AND a health and safety point of view. Whilst IBCs may be cube-shaped, which should allow them to be stacked, guidelines published … 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
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
© 2026 Thistle Systems
© 2026 Thistle Systems
