Multi-Level Mezzanine With Storage & Picking Automation - Prestige

Transforming Warehouse Space

In the ever-evolving world of storage and material handling, Prestige continually demonstrates its commitment to innovation and efficiency. Our recent project showcases not only our adaptability in the face of unexpected challenges but also our expertise in optimizing warehouse spaces with mezzanines, pallet racking systems, automated systems, and more.

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The Challenge: Adapting to Change

One of Prestige’s longest-time customers approached us in to maximize storage in a new expansion. While the original plan was to design a three-level traditional mezzanine that housed static rivet rack and shelving, the onset of the COVID-19 pandemic brought these plans to a halt, relegating the building to ground-level storage use.

A New Direction: Embracing Innovation

In , discussions resumed, but the pandemic’s impact on operations led the customer, Prestige, and other partners to reconsider the approach. The project evolved to focus on a more dynamic solution. After extensive evaluations of static, semi-automated, and fully automated systems, a decision was made. The optimal solution? A two-level structural mezzanine with a shelf-to-person storage and picking system, integrated with fully automated sortation. This choice was driven by both current needs and future projections.

The Solution: Maximizing Space and Efficiency

Key to this project was the design and installation of a multi-level mezzanine, making full use of the building’s 45’ clearance. This two-level structural mezzanine, manufactured by Wildeck and measuring 87’ D x 307’ W, provided an impressive 53,418 Sq Ft of additional space.

• Lower Level: Featuring ResinDek LD Flooring with a Grey Diamond Seal Finish, this level was engineered for heavy-duty use, supporting 125 PSF with maximum point loads of 1,400 lbs.
• Upper Level: Equipped with ResinDek HD Flooring and designed to support 125 PSF with maximum point loads of 2,780 lbs., this level houses a selective racking system for case storage, integral to the handpick operation.

Integrating Advanced Mezzanine Systems

The mezzanine levels are seamlessly connected through spiral vertical rise conveyors and powered accumulation roller conveyors, enabling effortless movement of products across all levels.

• Storage and Picking System: At the ground level, a shelf-to-person system leverages Automated Mobile Robots (AMRs) to enhance operational efficiency. These AMRs transport shelving units from beneath the mezzanine to operators for loading and unloading.
• Order Processing: Products are unloaded onto a sortation table for order accumulation, packing, and eventual conveyance for outbound shipping.

Conclusion: Setting New Standards

This project not only highlights Prestige’s ability to adapt and innovate in challenging circumstances but also our expertise in creating efficient, space-optimized storage solutions. By embracing advanced technologies and custom-engineered mezzanines, a conventional warehouse has been transformed into a state-of-the-art storage and picking facility.

Prestige continues to redefine warehouse optimization and space transformation, ensuring that our solutions not only meet current demands but are also poised for future challenges and opportunities.

Contact us today for more information on our storage solutions and to see how we can transform your warehouse space.

Your Questions Answered

Q: What is a mezzanine, and why is it useful for warehouse optimization?

A: A mezzanine is an intermediate floor or platform installed between the main floors of a building, typically used in warehouses to maximize usable space. It’s highly beneficial for warehouse optimization as it effectively doubles or even triples the available storage or operational area without the need for expanding the building’s footprint. This makes mezzanines a cost-effective solution for increasing storage capacity, improving organization, and enhancing operational efficiency in warehouse environments.

Q: How does the Multi-Level Mezzanine enhance warehouse efficiency?

A: By adding vertical storage space and integrating automated systems, the mezzanine increases storage capacity and streamlines picking and sorting processes.

Q: Can the mezzanine structure be adapted to different warehouse sizes?

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A: Absolutely. The modular design allows for customization to fit various warehouse dimensions and storage requirements.

Q: What safety measures are incorporated into the design?

A: The entire system is engineered with seismic considerations and the selective racking includes overhead cross-ties for stability, ensuring a safe environment for warehouse operations.

Q: How does the design of the Multi-level Mezzanine support different types of storage systems?

A: The Multi-Level Mezzanine is engineered to accommodate a variety of systems, from manual to fully automated solutions. Its versatile design allows for easy integration with different types of racking, shelving, and conveyor configurations, catering to diverse storage and retrieval needs. This flexibility ensures that the mezzanine can be utilized in various operations and processes, enhancing overall warehouse functionality and efficiency.

Small buildings with tall ceilings often face challenges in using their vertical space. Installing multi-level mezzanines is a highly effective problem solver here. These structures not only enhance the usability of a building’s existing footprint, but also offer numerous benefits across various industries, from office, retail to manufacturing and order fulfilment.

Multi-level mezzanines capitalize on previously unused vertical space, effectively doubling or tripling the floor area without extending the building’s footprint. This approach is particularly advantageous in warehouses and industrial settings where additional storage or production areas are essential. Industrial mezzanines allow businesses to increase their storage capacity and improve workflow efficiency, leading to enhanced productivity and profitability.

In retail and hospitality, mezzanines can create additional product display areas, dining spaces, or private function rooms, thereby enhancing customer experience and increasing sales potential. In office environments, mezzanines provide additional desk space, meeting rooms, and breakout areas, which can significantly improve employee productivity and satisfaction. Mezzanines are highly versatile and can be tailored to meet the specific needs of so many different industries.

Compared to traditional building extensions, mezzanines are a really cost effective option. Extensions can be expensive, time-consuming and messy, often requiring extensive permits and significant construction work. In contrast, mezzanines are clean, relatively quick to install and can often be constructed without disrupting ongoing business operations. This minimal hassle, coupled with the reduced need for planning permissions, makes mezzanines super attractive.

The design and installation of mezzanine floors involve several critical steps, including needs assessment, design and engineering, obtaining permits, and ensuring compliance with safety regulations. Customisable options such as different flooring materials, balustrades, and staircases allow businesses to specify the deign of a mezzanines that align perfectly with their brand and functional requirements. This customisation ensures that the mezzanine not only meets practical needs but also enhances the aesthetic appeal of the space.

Investing in a mezzanine floor offers long-term benefits. These structures are durable and can be dismantled and relocated if needed, making them a flexible solution for growing businesses. By maximising the use of vertical space, businesses can avoid the significant costs and logistical challenges associated with moving to a larger premises, thereby maintaining continuity and stability.

Multi-level mezzanines present a practical, cost-effective, and versatile solution for small buildings with tall ceilings, enabling businesses to fully leverage their available space and enhance operational efficiency.

When it comes to fulfilling your dream mezzanine project, you are in safe hands with the experience that Mezz Floors UK brings. We are here to help, feel free to reach out today.

Contact us to discuss your requirements of multi level mezzanine. Our experienced sales team can help you identify the options that best suit your needs.