When Unilever’s Research & Development team at their Sharnbrook site started reviewing how their space was being used, one thing became clear. The way stock was stored no longer matched how the site was operating day to day. As the volume and variety of equipment, materials and consumables grew, so did the pressure on the existing layout.

They needed more than just extra storage. The objective was to improve flow, increase capacity and make sure the space could support how the site would work in the future, not just now.

That’s where BSE UK came in.

Here, we take a look back at the details of the project.

Understanding the warehouse storage challenge

Unilever approached BSE UK looking for a practical, scalable warehouse storage solution that would support several different areas across the site. Adam Griffiths from the Unilever team explained that they needed a mix of pallet racking and boltless shelving, alongside the relocation of some existing racking to improve overall layout and efficiency.

The key challenge was space. The footprint of the building was fixed, but the demands on it were increasing. Different departments had different storage needs, from palletised goods in the dry store, through to boxed items, archives, cleaning supplies and engineering equipment.

It wasn’t just about fitting more in. It was about creating a system that made sense operationally. Clear access routes, safe working practices and flexibility for future changes were all part of the brief.

Designing the right pallet racking system

Simon Lock from BSE UK led the design of the new pallet racking installation, starting with the dry store. This area needed to handle both Euro pallets (800mm x 1200mm) and standard pallets (1000mm x 1200mm), while making the most of a compact space.

Rather than defaulting to wide aisles, Simon designed a layout with slightly narrower aisles to maximise pallet capacity without compromising safety or usability. This allowed Unilever to achieve the pallet numbers they required within the available footprint.

The system was built with multiple levels and durable wire mesh decking. This gave Unilever the flexibility to store non-palletised items on upper levels, which was particularly useful for mixed stock and irregular items.

Each bay was designed to handle up to 12,000kg, with 3,000kg per level, providing the strength and reliability needed for a busy R&D environment.

Because of the tighter aisle widths, Simon specified the use of Bendi or Flexi articulated trucks. These trucks have a much smaller turning circle than traditional forklifts, making them ideal for narrow aisle pallet racking. This choice ensured the system would not only fit physically, but also work smoothly in practice.

Reconfiguring their existing storage layout

Alongside the new pallet racking installation, Unilever also wanted to make better use of their existing assets. Part of the project involved dismantling an existing pallet racking system and reinstalling it in their Reserve Equipment Store.

The brief here was simple: reuse what was already available, with only new floor fixings and a small number of additional bays added where needed. This approach kept costs under control while still delivering a meaningful improvement in how the space was organised.

By relocating and reconfiguring the racking, Unilever were able to create a more logical flow between areas, reduce congestion and free up valuable space in key operational zones.

Boltless shelving for multiple departments

Beyond pallet storage, several departments required a different type of solution. Heavy duty boltless shelving systems were installed across the Cleaning Store, Archive Stores, Furniture & Equipment Store and Apleona Engineering Stores.

These areas needed easy access, clear visibility and shelving that could adapt as requirements changed. Boltless shelving was the ideal fit.

The systems were fitted with chipboard shelves in widths ranging from 1830mm to 2135mm, tailored to suit each space and the items being stored. Finished in painted grey beams with blue frames, the shelving provides a clean, consistent look across the site.

Each level is capable of holding up to 500kg, which was more than sufficient for Unilever’s needs, while still allowing teams to reconfigure shelf heights as stock profiles evolve.

Racking installation and delivery

The full project was delivered by the SEIRS installation team, working closely with BSE UK and Unilever to ensure minimal disruption to daily operations. SEIRS operates under SEMA to ensure that storage equipment installers meet industry standards for competence and safety.

Specialist equipment, including scissor lifts and forklift trucks, was used throughout the installation process to ensure everything was completed safely and efficiently.

From initial design through to final handover, the focus remained on creating a storage system that felt like part of the building, not an add-on. Every area was designed around how people actually use the space.

A solution built around real needs

What makes this project stand out is not the scale, but the thinking behind it. This wasn’t about installing as much racking as possible. It was about understanding how the site operates, where the pressure points were, and what Unilever needed from the space over the long term.

The result is a warehouse storage solution that supports:

• Higher pallet capacity within the same footprint
• Safer, more efficient movement through the use of articulated trucks
• Flexible storage for mixed stock and changing requirements
• Better organisation across multiple departments
• A layout that can adapt as the site continues to grow

It’s a good example of how warehouse fit out projects work best when they start with real operational objectives, not just product specifications.

Simon Lock on the project

Simon Lock, who led the design of the solution, reflected on the project:

“Pallet racking and boltless shelving are the core of what BSE UK have been doing for more than 50 years. Projects like this are always a pleasure to work on, to discuss the requirements of the customer and then design a solution that fully suited to what they need. It’s rewarding to see how it benefits them. Great to work with Alex on this. Thank you.”

BSE UK: Creating smarter spaces for growing businesses

For BSE UK, this project with Unilever is a clear example of what modern warehouse storage should look like. Rather than a racking-first approach, a carefully planned environment that supports how people work, how stock moves and how the business is likely to evolve.

Whether it’s pallet racking installation, boltless shelving or full warehouse reconfiguration, the real value comes from understanding the customer first. Their challenges, their constraints and their goals.

In Unilever’s case, the outcome is a smarter, more efficient R&D facility that can handle current demand and stay flexible for whatever comes next. And that’s exactly what good storage design should achieve.

If you’ve got an upcoming storage project and want to talk through your options, you can call the BSE UK team on 0117 955 5211, email info@bse-uk.co.uk, or book a free site survey to see what’s possible in your space.

The post Pallet Racking & Boltless Shelving Installation for Unilever’s R&D Facility appeared first on BSE UK.

 

Skin Cupid, a rapidly growing Korean skincare brand renowned for its focus on skin health and beauty, offers a diverse range of products enriched with natural, nourishing ingredients. As the brand's popularity has soared, so has its demand. To keep up with growth and maintain operational efficiency, Skin Cupid made the strategic decision to move its storage operations from a London facility to a larger warehouse in Peterborough.

 

The Challenge: At their new premises, Skin Cupid faced the need for a tailored storage system that could accommodate their palletised goods and streamline picking operations. The goal was to create a solution that maximised storage capacity, ensured efficient workflows, and supported the brand's commitment to delivering premium quality skincare products to their growing customer base.

 

The Solution: Skin Cupid reached out to BSE UK in July 2024 to design and implement a storage system for the new warehouse. Storage specialist, Matt, visited the site to assess the available space and measure up, whilst considering factors such as headspace and the warehouse workflow. The solution had to ensure seamless goods inward and picking operations, crucial for Skin Cupid to meet increasing demand.

 

Following this site visit, Matt provided a detailed proposal, which included:

• Adjustable Pallet Racking: Custom designed with timber decks, ideal for storing pallets of products, and featuring specific labelling with SKU codes for easy identification.
• Racking Protection: End barriers and post guards to ensure the safety and longevity of the storage system.
• Short Span Shelving: Tailored shelving to accommodate picking operations, complete with a clear labelling system for easy identification of each SKU – therefore streamlining order fulfilment.
• Workbenches: High quality workstations to facilitate efficient packing of orders for shipment to customers.
• Conveyor: Designed to speed up the workflow from picking to packing, the conveyor system ensures a seamless transition of products, reducing manual handling and increasing operational speed and efficiency.

The design and layout were carefully designed to ensure Skin Cupid could operate at maximum efficiency while maintaining the highest standards of quality.

 

Implementation: Once the proposal was approved, the installation process was scheduled to begin in August 2024. With a four week timeframe to complete the project, Project Manager Ollie Dulley oversaw the entire installation, working closely with both BSE UK’s SEIRS registered installers and the client.

 

Results: The new storage solution has significantly improved Skin Cupid’s ability to manage inventory and fulfil orders more efficiently, directly supporting their growth and ability to meet consumer demand. The optimised layout ensures an efficient workflow from goods receipt to picking and packing, allowing the brand to maintain the quality and speed of service expected by their customers.

The post Optimising Warehouse Storage for a Growing Skincare Brand appeared first on BSE UK.

CLIENT BACKGROUND

BSE UK partnered with a leading retail brand to enhance their warehouse storage capabilities and increase storage space at their location in Peterborough.

LOCATION

Peterborough

OBJECTIVE

To supply and install a comprehensive pallet racking solution that maximizes storage capacity and ensures efficient warehouse management by integrating with the client’s Warehouse Management System (WMS).

SCOPE OF WORKS

Install Pallet Racking

Following a site survey and the successful acceptance of a quote, BSE UK supplied and installed 4,000 pallet racking locations at 13m high, creating significant storage space within the location.

RACK LABELING

A comprehensive rack labelling system was implemented to seamlessly integrate with the client's Warehouse Management System.

This system includes clear and standardised labels on each rack, supporting efficient inventory management and improved visibility. By integrating with the WMS, the rack labelling system enables real-time tracking of inventory.

SAFETY FEATURES

A pallet backstop system was installed throughout the racking for enhanced safety. Additionally, racking protection measures including rack end barriers and upright guards were integrated for more comprehensive protection which contributes to a safer working environment.

FINISH

The beams were painted with a special black finish in order to align with the client’s bespoke branding specifications, reinforcing the brand’s identity throughout the location.

RESULTS

The successful completion of the project resulted in significant improvements for the client including:

• Increased storage capacity to accommodate 4000 pallet locations
• Improved warehouse safety with pallet backstop systems, rack end barriers, and upright guards; reducing the risk of accidents and damage to stock within the warehouse.
• Seamless integration with the client’s Warehouse Management System through effective rack labelling, contributing to greater efficiency and better inventory management.

Additionally, the project was completed on budget and ahead of the program.

Check Out the Project Gallery Below

If you’d like to find out more about this project or how we could support your business, give us a call today on 0117 955 5211 or book a site survey with our expert team.

 

The post Pallet Racking Installation | Peterborough appeared first on BSE UK.

CLIENT BACKGROUND

A client based in Park Royal, London, required an overhaul of their existing pallet racking system to accommodate a new product line.

LOCATION

Park Royal, London

OBJECTIVE

To modify and extend the existing pallet racking infrastructure to suit the requirements of the new product line. This included stripping down and rebuilding their existing racking and installing mesh enclosures, guide rails and end barriers.

CHALLENGES

The project faced the challenge of stripping and installing the new racking within a tight timeframe while ensuring minimal disruption to ongoing operations. To ensure the project was ready for the new product line, installation needed to be completed within 4 weeks.

SCOPE OF WORKS

Strip and Rebuild Pallet Racking:

BSE UK dismantled the existing pallet racking setup and rebuilt it to the new design specification. This involved configuring different bay types and levels to increase storage capacity. The specification included:

Bay Type 1 

• 7000mm H x 2500mm D x 3000mm clear entry.
• 3 timber decked levels per bay.
• 6000Kgs SWL per bay.

Bay Type 2

• 6000mm H x 1000mm D x 3000mm clear entry.
• 14 timber decked levels per bay.
• 6300Kgs SWL per bay.

Layout Details

• 1 single entry run comprising of 9 type 1 bays.
• 1 single entry run comprising of 9 type 2 bays.
• 2 double entry runs comprising of 9 type 1 bays back to back.
• 1 double entry run comprising of 9 type 1 bays on one side and 7 type 1 bays on the other side.

Mesh Cage Installation:

BSE UK installed 2 mesh enclosures to secure specific sections of the space, with a 4 sided enclosure and 3 sided enclosure at the end of the pallet racking. The specifications included angle frame steel partitioning, 2” x 2” x 10g mesh and a selection of finish options to meet the client's requirements. Enclosures were configured to accommodate single and sliding doors.

Guide Rails and End Barriers:

The project included the installation of racking protection including guide rails and end barriers to improve safety and reduce the risk of accidents. The specification included:

• 8 runs of 28m guide rail including 3 double lead ins and 2 single lead ins.
• 1 tubular end barrier 500mm high x 1000mm wide.
• 7 tubular end barriers 500mm high x 2500mm wide.

FINISH

To improve durability and deliver the project to the client’s specification, beams were painted orange and frames were painted blue.

ANTI-COLLAPSE MESH

Full-height anti-collapse mesh was installed across all designated runs as part of the project, with specified dimensions and finish to meet the client’s requirements.

RESULTS 

The successful completion of the project resulted in significant improvements for the client including:

• Enhanced Storage Capacity
• Improved Safety
• Minimal Disruption
• Improved Accessibility
• Improved Efficiency for the New Product Line

Additionally, the project went ahead of schedule and was completed within 3 weeks, 1 week ahead of schedule.

 

Check Out the Project Gallery Below

If you’d like to find out more about this project or how we could support your business, give us a call today on 0117 955 5211 or book a site survey with our expert team.

 

The post Pallet Racking Installation | London Case Study appeared first on BSE UK.

CLIENT BACKGROUND

BSE UK was approached by a client in Blackwood, South Wales, to remove their existing racking and install new drive-in pallet racking to maximise storage space in their warehouse.

LOCATION

South Wales, Blackwood

OBJECTIVE

To strip down an existing block of drive-in racking and supply, deliver and install two new blocks of drive-in racking at the client's site in Blackwood. Installation would be carried out during normal working hours, with weekend working available as required.

CHALLENGES

The client faced the challenge of maximising storage space while maintaining accessibility and reducing the risk of damage to stock. Their existing drive-in pallet racking system required an overhaul to meet their growing needs.

SCOPE OF WORKS

Strip Down Existing Drive-In Racking:

BSE UK stripped down, stacked and banded the existing block of drive-in racking for removal by a contractor. The pallet and block details were:

• Pallet Details: 1420mm W X 1020mm D X 1500mm H @ 1250Kgs per pallet.
• Existing Block Details: 8 lanes wide x 4 pallets deep x 4 pallets high (ground + 3 levels).

New Drive-In Pallet Racking:

BSE UK installed new drive in pallet racking at the customer’s location, with two blocks installed:

Block 1

• 16 lanes wide consisting of:
• 13 lanes 5 pallets deep x 4 pallets high (ground + 3 levels).
• 2 lanes 5 pallets deep x 3 pallets high (ground + 1 level).
• 1 lane with no pallets.
• Total Pallet Count – 290.

Block 2

• 3 lanes wide x 2 pallets deep x 4 pallets high (ground + 3 levels).
• Total Pallet Count – 24.

FINISH

Rails, frames and arms were all pre-galvanized to offer a durable finish that will protect the components from damage. The arms were painted blue.

 

ACCESSORIES

Full rack protection was installed to minimise the risk of damage and protect stock. Rack protection accessories included entry headers, rear stops, guide rails and an additional beam for each pallet level. Additionally, spine bracing was supplied and installed for the rear of the 5 lanes.

 

ANTI-COLLAPSE MESH

Full-height anti-collapse mesh for all 3 runs was installed as part of the project, with specified dimensions and finish to meet the client’s requirements.

 

RESULTS 

The implementation of the new drive-in pallet racking system offered significant benefits to the client including:

• Increased Storage Capacity
• Improved Accessibility
• Minimal Disruption
• Forklift Access
• Robust & Low Maintenance System

 

Check Out the Project Gallery Below

If you’d like to find out more about this project or how we could support your business, give us a call today on 0117 955 5211 or book a site survey with our expert team.

 

The post Drive-In Pallet Racking Installation | Blackwood Case Study appeared first on BSE UK.

COMPANY

Wales & West Utilities Ltd have been transporting gas to businesses and homes around wales and the south west of England, they launched in 2005 and have since been helping 7.5 million people stay safe and warm with a gas connection that they can rely on.

CUSTOMER

https://www.wwutilities.co.uk/

LOCATION

Bristol.

PROJECT BRIEF

Salesperson: Matt Aldred
matt@bse-uk.co.uk
To supply and fit mesh cages, still partitioning and cloakroom benches for site in Bristol.

PRODUCTS USED

BSE UK Supplied 2 mesh partitions chambers with singe doors to each.

1 run of 8 mesh cages 1800mm high x 600mm deep x 400mm wide each cage to be split into 3 with 18mm chipboard levels.

2 runs of 7 mesh cages 1800mm high x 1000mm deep x 500mm wide each cage to be split in two with 18mm chipboard level giving a total of 52 mesh cadges.

The post Mesh Cage and Lockers Case Study appeared first on BSE UK.

CUSTOMER

Pallet Racking for a global logistics provider who recently opening a new warehouse in Avonmouth, Bristol.

LOCATION

Avonmouth, Bristol

PROJECT BRIEF

Salesperson: Matt Aldred
matt@bse-uk.co.uk
To supply and install new heavy duty pallet racking with timber decking and full rack protection system.

PRODUCTS USED

BSE UK supplied and installed 7000mm pallet racking for a logistics client where flexibility was the name of the game. As a logistics provider, the clients' racking needs could change at any time in the future. Adjustable Pallet Racking offered the perfect mix of increased pallet capacity whilst futureproofing for ever changing business needs.

Then New AR Pallet Racking was installed to give the customer 2,000 pallet spaces, all with open boarded timber decking allowing safe and easy storage of pallets.

Contact BSE UK today for your Warehouse Racking Requirements - Speak to the Experts on 0117 955 5211 - or email info@bse-uk.co.uk

 

The post Pallet Racking Bristol – Case Study appeared first on BSE UK.

COMPANY

Tubex opened its factory in south wales in the 1980’s producing treeshelters, and quickly became one of the most popular on the market. The factory today is three times the size it originally was. The business now focuses on a wider range of products for all trees and vines their products are used in the forestry, viticulture, landscaping and fruit markets.

CUSTOMER

https://tubex.com/

LOCATION

Aberdare, South Wales.

PROJECT BRIEF

Salesperson: George Ives
george@bse-uk.co.uk
BSE UK were asked to supply and fit drive in racking and rack protection in a storage area of the factory to give more pallet locations within the space available.

PRODUCTS USED

Drive-In Racking
11 Lanes wide x 4 Pallets deep x 2 Pallets high
Polymer Pallets = 11 lanes x 4 deep x 2 high = 88 no. Pallets
Total Pallet Count: 88 no. Pallets
Overall Length: 16,460mm
Overall Depth: 4,721mm
Overall Height: 4,883mm max.

Drive-In Racking Protection System
To supply and install, entry guides, floor mounted pallet stop, guide rail and upright protectors to all uprights.

CUSTOMER COMMENTS

“BSE UK have been brilliant from start to finish, the sales and installation teams were very knowledgeable and answered any questions I had.

This is the first time we have used drive in racking at our site but BSE UK were able to support us in using the racking in the correct way. I’m very happy with the racking and I will definitely be using BSE UK again"

Darren Bright, Project manager

Download the full case study here

The post Drive In Pallet Racking – Tubex Berry appeared first on BSE UK.

COMPANY

Daikin have more than 90 years of experience in air conditioning which makes it possible for them to offer the most comfortable, energy efficient, and reliable solutions available within their market.

CUSTOMER

https://www.daikin.com/k/

LOCATION

Thornbury, Bristol.

PROJECT BRIEF

Salesperson: George Ives
george@bse-uk.co.uk
BSE UK were contacted by Daikin to help provide a solution for more storage space using the already limited space they had in their warehouse.
Daikin had been looking at options to rent out another warehouse space for storage.
BSE UK were able to provide a mezzanine floor solution over an existing shelving and caged area allowing additional storage whilst maintaining useable floor space below. .

PRODUCTS USED

Mezzanine floor
with a Total Floor Area of 132.24 m2 And one standard staircase
Building Regulation Application
BSE UK made the application on the behalf of our client using an Approved Inspector, including all required drawings, structural calculations and all correspondence.

CUSTOMER COMMENTS

‘’Working with BSE UK previously we knew what to expect, the service was quick and efficient from quote to installation.
They were able to provide us with a mezzanine floor solution that fixed our storage problems and allowed us to keep the existing floor space and storage layout.
We would not hesitate to use BSE UK for any future projects or to recommend them to anyone looking for any storage requirements.’’

Dan Blanchard, Depot Manager

Download the full case study here

The post Mezzanine Floor Case Study – Daikin appeared first on BSE UK.

COMPANY

Norbord Europe Ltd are a world-leading manufacturer of engineered wood based products to service the construction, furniture and DIY industries.

CUSTOMER

https://www.norbord.co.uk/

LOCATION

South Molton, Devon

PROJECT BRIEF

Salesperson: George Ives
george@bse-uk.co.uk
To strip down existing racking and supply deliver and install New pallet racking in warehouse with timber decking and anti-collapse screens.

PRODUCTS USED

Firstly BSE UK stripped down existing pallet racking and removed from site.

Then New AR Pallet Racking was installed to give the customer 1,272 pallet spaces, all with open boarded timber decking allowing safe and easy storage of pallets.

We also installed Anti Collapse Mesh screens to protect walkways and stop products being pushed through and falling from the racking by forklifts. Improving safety within the warehouse for staff and any visitors.

CUSTOMER COMMENTS

“From the initial inquiry through to the completion of the job, we received numerous site visits and communication to ensure everything was correct.
On day one of the installation we made some last minute amendments to the layout and design of the project. Any changes were looked over by the project co-ordinator Paul and updated on the drawings for the installation team.
The job was completed ahead of schedule to a high standard. I would definitely recommend BSE UK, in fact I already have to numerous colleges"

Steve Gardiner, Maintenance Planner

Download the full case study here

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