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.

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

Veetee Rice was founded in 1987, from then on it has been one of the UK’s largest rice suppliers. They supply rice to major supermarkets and to over 50 countries worldwide. Having won multiple awards over the last 10 years Veetee are recognised as a key player in the international food market.

CUSTOMER

https://www.veetee.com/

LOCATION

Kent

PROJECT BRIEF

Salesperson: Dennis Ives
Dennis@bse-uk.co.uk
BSE UK were asked to supply, deliver and install Pallet Racking and Live Storage within a new area in Veetee's Rochester storage and distribution centre. Gaining as many pallet locations as possible within the space.

PRODUCTS USED

This project included a mixture of AR Adjustable Pallet Racking and live storage giving the customer 3974 pallet locations.
In order to gain as many pallet locations as possible height was utilised with 11.5m uprights. In order for this warehouse to be completely functional in correlation with an existing warehouse a walk through pallet bay were installed allowing storage of pallets above the walk through aisle.
There was also a section of live storage installed at the loading bays to assist with deliveries and collections. There was also restricted height locations, these were marked with yellow coloured beams.

Download the full case study here

The post Case Study – Pallet Racking For VeeTee Rice appeared first on BSE UK.

COMPANY

Nissin (UK) Ltd. are owned by the Nissin Corporation based in Japan. A London branch was opened in 1975 and in 1983 it became an independent subsidiary. Nissin (UK) Ltd. established operations in Swindon, West Drayton, and Rugby. Nissin’s traditional business in Air & Ocean Freight Forwarding, Customs Brokerage and Warehousing has provided a solid background to enter the increasingly dynamic global transportation markets, with services such as third party logistics and supply chain management.

CUSTOMER

http://nissinuk.com/

LOCATION

Swindon, Wiltshire

PROJECT BRIEF

Salesperson: George Ives
george@bse-uk.co.uk
BSE UK were contacted by Nissin UK as they had a new customer that needed 1000 pallet location in less than 2 weeks. BSE UK were able to supply and install within the time frame thanks to holding a good level of stock.

PRODUCTS USED

AR Pallet Racking
Bay Details
Bay Type 1
9000mm H x 1100mm D x 2700mm c/e
Ground + 4 Beams Levels per Bay
Bay Type 2
9000mm H x 1100mm D x 950mm c/e
Ground + 4 Beams Levels per Bay
Load Data
To suit Euro Pallet 1900mm High 500Kgs per Pallet
Bay Type 1
1500Kgs per Beam Level, 6000Kgs per Bay
Bay Type 2
500Kgs per Beam Level, 2000Kgs per Bay

Anti Collapse Mesh Screen
To supply and install Anti Collapse Mesh Screen to protect walkway behind.
Screen 9,000mm High x 25,150mm Overall Length.

CUSTOMER COMMENTS

"BSE UK were the only company I went to that could deliver the lead time we needed, the job ran smoothly and everything was installed within the time frame promised.
I was very impressed with the responsiveness and knowledge of the salesman, I would always have the answer to my questions within the same day.
We have already had BSE UK back to complete rack inspections at all 3 of our sites. Going forward I would use BSE UK as a preferred supplier within Nissin UK."

Download the full case study here

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

CUSTOMER COMMENTS

‘’I contacted BSE UK, as I wanted to maximise the little space I had left in the warehouse.

George came to site and told me what options I had, he was very knowledgeable and provided me with brilliant information on what benefits the various different products would give me.

BSE UK also offered good ideas to maximise pallet locations, like adding single pallet racking bays to the end of the cart push back system.‘’

CUSTOMER

Pharmaceutical Manufacturer

LOCATION

North Devon

PROJECT BRIEF

Salesperson: George Ives
george@bse-uk.co.uk

With their warehouse running at 90% capacity, there was an urgent need to gain more storage from the little space they had left. BSE UK were invited in to measure up and provide an efficient system in order to maximise the available warehouse space and increase the number of pallet locations.

PRODUCTS USED

2 Deep Cart Push Back Pallet Racking
Frame Size - 5500 mm high x 2550 mm deep
Accessories - Push back Carts
Layout - 1 off block 21 wide x 2 deep x 4 high

Pallet Load Details:
Pallet type - Chep
Width - 1000mm
Depth - 1200mm
Max pallet weight - 1000 kg

Basic Channel Parameters:
Nested Height - 123 mm
Recommended slope - 3.0%

Features:
Rail colour - Grey
Upper carts colour - Grey
Lowest cart colour - Black
Multipurpose plates - 2 off
Anti lift out protector - Yes
Linked carts for safety - Yes
Flanged wheels - Yes
Loading guide - Yes

Truck Details:
Type of truck required Fork lift with tiltable mast/ fork

Standard Pallet Racking
2 no. Single Entry racks @ 1 Bay Long
5000mm H x 1100mm D x 2250mm c/e
Ground + 3 no Beam Levels per Bay

Download the full case study here

The post Cart Push Back Pallet Racking Case Study appeared first on BSE UK.

COMPANY

Strickland MFG are Europe’s largest supplier of a wide range of parts for earth-moving and demolition/recycling equipment including couplers, excavator buckets, grapples and pulverisers. They offer in-house design and a wide range of off-the-shelf products to their customers.

COMPANY

https://www.stricklanduk.com/

LOCATION

Evesham, Worcestershire.

PROJECT BRIEF

To supply and install External Pallet Racking and Anti-Collapse Mesh at Strickland’s site in Evesham, Worcestershire.

PRODUCTS USED

Bay Set Up
4500mm h x 900mm d x 2700mm clear entry
3 no. Beam levels per bay

Finish
Beams – Coated for External Use
Frames – Galvanised

Load Data
Beams – 3000kg UDL per level
Frames – 9000kg SWL per bay

Layout Details
1 no. single entry run comprising of 2 bays (overall length approx. 5700mm)
This run to have anti collapse mesh fitted to the rear of the run
3 no. double entry runs comprising of 2 bays (overall length approx. 5700mm)

CUSTOMER COMMENTS

“After being let down by a local company, BSE UK were fast to respond and reliable.

They provided me with a very competitive quote, and the quality of the products is brilliant.
I’m so pleased with the project and will definitely be turning to BSE in the future.‘’

Nigel Hutchings, Warehouse Manager.

Download the full case study here

The post AR External Pallet Racking Case Study – Strickland MFG appeared first on BSE UK.

BSE UK recently undertook work for Lens Online, a company that is part of the well known opticians, Specsavers. Lens Online’s warehouses are stocked with fragile lenses and other associated equipment, which needs to be well organised and available for easy picking without any risk of damage.

Initial Brief

Following an initial conversation and site visit, Dexion P90 Pallet Racking with Interoll Carton Flow System was recommended and installed. Pictured below is the P90 Pallet Racking system.

Products Used Dexion: P90 Pallet Racking

Dexion P90 wide aisle pallet racking is one of the most flexible and economical racking systems we have available at BSE UK, access to pallets is unrestricted and systems can be built up to 30 metres high with no limitation on the layout, this is what makes the P90 such a reliable go-to option for a wide range of picking operations.

In addition to being so flexible, Dexion P90 pallet racking can be adapted to meet your business needs through a wide range of accessories including column guards, aisle marking systems and flow systems as shown below.

Interoll Carton Flow System

A key product used within the racking system of this job was the Interoll Carton Flow System, designed to improve the flexibility of the picking process in distribution and fulfilment centres.

You can see the flow system in action below, with products gently rolling to the front of the racking system allowing for easy operative-facing picking with zero damage to the stock.

These systems of great flexibility in operations where dimensions and weights of goods vary, and with 90% space utilisation – your valuable racking space isn’t going to waste.

Bay Types

6 different bay types were used throughout the job to ensure that Lens Online had storage solutions available for all their different products:

Bay Type 1 – 2700mm clear entry bay x 2000mm high frame x 1100 deep each face.

• Each bay fitted with 6 carton flow levels.

Bay Type 2 – 2700mm clear entry bay x 2000mm high frame x 2200mm deep each face.

• Each bay fitted with 6 carton flow levels.

Bay Type 3 – 2700mm clear entry bay x 7500mm high frame x 1100 deep each face.

• Each bay fitted with 6 full depth carton flow levels with 3 pallet levels above

Bay Type 4 – 2700mm clear entry bay x 7500mm high frame x 1100 deep each face.

• Each bay fitted with 4 pallet levels
• All levels fitted with open boarded timber decking
• Rack protection included for all uprights

Bay Type 5 – 1350mm clear entry bay x 2500mm high frame x 1100 deep each face,

• Each bay fitted with 1 pallet level
• All levels fitted with open boarded timber decking
• Rack protection included for all uprights

Bay Type 6 – 2700mm clear entry bay x 2500mm high frame x 1100 deep each face

• Each bay fitted with 1 pallet level
• All levels fitted with open boarded timber decking
• Rack protection included for all uprights

Talk To The Experts

Lens Online were delighted with their new racking system, allowing for a faster, flexible and more efficient picking process in their warehouse.

If you have questions regarding the Dexion P90 pallet racking, Interoll Carton Flow System or any of our other products – give one of our expert team a call on 0117 955 5211.

The post Dexion P90 Pallet Racking With Carton Flow System Case Study appeared first on BSE UK.

BSE UK recently completed a job for Robbins Timber, a well established timber company providing a range of plywoods, hardwoods, softwoods and associated products.

Their warehouses fulfill orders worldwide and are packed with a range of different products.

Initial Brief:

The objective was to supply, deliver and install a vertical racking solution to keep their timber products stored safely, as well as being better organised for improved stock control and faster, more efficient picking.

Robbins Timber were provided with a detailed schematics drawing with 3 different layout options before the work went ahead:

Products Used – Vertical Racking Solution

BSE implemented Dexion vertical storage racking on their site, this type of racking is designed to make use of overhead space and is suitable for tall items. Using this type of racking allowed for the timber to be stored vertically, reducing the risk of damage and consumation of space that comes with horizontal storage.

Holding stock of several different types of hard and soft woods, the racking system was fitted with 2 adjustable beam kits pictured below.

These adjustable beams not only help support the wood to avoid damage from leaning, but also allow for the separation of products to keep them better organised; with plenty of room inbetween the racking for warehouse operatives to pick and deliver items. 

4 different bay types were used throughout the job to ensure that Robbins Timber had adequate storage solutions for the different shapes and sizes of timber that they deal with:

Bay Type 1 – 4200mm high x 2700mm clear entry x 900mm deep – 6 dividers bars over 2 levels.

Bar Type 2 – 4200mm high x 1350mm clear entry x 800m deep – 4 divider bars over 2 levels.

Bar Type 3 – 4200mm high x 2700mm clear entry x 800mm deep – 6 divider bars over 2 levels. The storage level for bay type 3 was set at 1280mm and fitted with steel decking panels to allow for storage space underneath.

Bay Type 4 – 4200mm high x 3300mm clear entry x 900mm deep – 8 divider bars over 2 levels.

Feedback From Robbins Timber

“Dealing with vast amounts of timber on a regular basis, it was important that we had the correct and most efficient storage solutions in place.”

“After listening to our initial requirements, 

BSE UK recommended a vertical racking system fitted with adjustable beams to support the timber.”

“The job was done professionally and efficiently – BSE kept up informed on what they were 

doing throughout the installation and we were very impressed with how well it was managed from speedy initial quotation to final installation.”

“I would have no hesitation in recommending BSE UK.”

Ben Bagnall - Robbins Timber

Talk To The Experts

Another happy client for BSE UK – Robbins Timber can now rest assured that their timber is stored as efficiently as possible, maximising space in their warehouse.

If you have any questions regarding vertical racking systems or are looking for a reliable storage expert to help you with your next project, give one of our expert team a call on 0117 955 5211.

The post Robbins Timber – Vertical Timber Storage Racking Case Study appeared first on BSE UK.