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.

Initial brief

BSE UK were invited in to this site in Essex by an existing customer after completing succesful projects at numerous sites across the UK. With a limited area for small parts storage, a mobile shelving system was chosen as the optimum solution.

Dexion P90+ Pallet Racking was also installed for storage of heavy motors. The racking was fitted with heavy duty steel decking panels to enable storage of motors that vary in weight and size. To improve ergonomc performance and a great health and safety feature is the introduction of Dexion Pull Out Units that enable low level pallets to be pulled out and picked from safely.

Project Summary:

• BSE UK invited to survey, design and quote for installation of mobile shelving for small parts storage
• Space maximised using a mobile system
• Dexion pallet racking with steel decking and pull out units for increased safety
• BSE UK carried out installation in Essex using SEMA approved installation team

Dexion Hi80 Shelving on Mobile Base - Full Height Dividers used to create pigeon holes

Dexion Mobile Shelving and Dexion Racking with Pull Out Units

Dexion Mobile Shelving - Perfect for Maximising the space in your Warehouse - Call now 0117 955 5211 or email info@bse-uk.co.uk

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Client: Amazon.co.uk

Amazon, is an American electronic commerce and cloud computing company, founded on July 5, 1994, by Jeff Bezos and based in Seattle, Washington. It is the largest Internet-based retailer in the world by total sales and market capitalization.

Location: Coalville, Leicestershire

Products:  Dexion HI280 Shelving and Dexion P90 Pallet Racking

Initial Brief:

BSE UK were invited to quote for stores area shelving at a new Amazon distribution centre in Coalville, Leicestershire. Having previously kitted out the stores area for Amazon in Swansea, the client wanted to replicate the specification previously supplied.

Project Summary:

Installation of stores shelving for small parts storage and pallet racking with pull-out dividers for palletised loads. Bristol Storage specified Dexion HI280 shelving with full height dividers to each level. Dexion P90 pallet racking was also specified as the perfect racking solution. Pull out units were fitted to the ground level racking locations to enable picking directly from pallets.

Dexion P90 Pallet Racking with Pull Out Units

Dexion HI280 Shelving System with Full Height Dividers

Specification

Dexion HI280 Shelving

Bay Details

• 2100mm High x 1000mm Wide x 600mm Deep
• 6 Shelf Levels per Bay

All bays fully clad – steel cladding to side frames and back

Load Data

• 140 Kgs per Level
• 840Kgs per Bay

Dexion HI280 Dividers

• 3 no. Dividers per level (5 Levels per Bay)
• Total 1050 off. Dividers 400mm H x 600mm Deep
• Fully removable and relocatable dividers for optimum flexibility.
  Dexion P90 Racking

Bay Details

• 2500mm High x 2700mm Wide x 1100mm Deep
• 3 Beam Levels per Bay
• Each Level fitted with Steel Decking Panels

Load Data

• 2000 Kgs per Level
• 6000Kgs per Bay

Dexion P90 Pull Out Units

• Pull Out Units to be fitted to ground level of each racking bay. 2 units per bay.
• Load Capacity up to 1000Kgs per unit
• Finished in RAL 5010 Blue

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