Intelligent Racking Retrofit Project for an E-commerce Warehouse

Ho Chi Minh City

Intelligent Racking Retrofit Project for an E-commerce Warehouse - 1

Challenge

The client's e-commerce warehouse in Ho Chi Minh City originally spanned 800 square meters, with a space utilization rate of less than 40%. The traditional floor-stacking method resulted in extremely low manual picking efficiency, with a maximum daily throughput of only 500 orders, falling far short of peak season demands. Furthermore, disorganized cargo classification made inventory counting both time-consuming and labor-intensive.

Solution

Our company designed and installed a customized heavy-duty pallet racking system for the client, featuring a rack height of 6 meters and compatibility with narrow aisle electric forklifts. A total of 120 rack sections were installed throughout the warehouse, increasing storage density by 60% compared to the previous layout. Simultaneously, we optimized the slotting and location coding system and introduced a barcode scanning picking process, boosting daily order processing capacity to 1,500 orders. The project took 14 days from site survey to completion, with normal warehouse operations maintained throughout the construction period.

800
m² Area
3000
kg Load Capacity
14
Project Duration
60%
Space Improvement
This project is a flagship case study for our company in Vietnam’s e-commerce warehousing sector. The client is a cross-border e-commerce enterprise specializing in apparel with over 3,000 SKUs. Prior to the renovation, the warehouse had limited floor load-bearing capacity, forcing goods to be stacked in a single layer and resulting in a severe waste of vertical space. The core of the solution involved implementing our VN-H3 heavy-duty pallet racking system, featuring a load capacity of up to 3,000kg per level to meet the storage requirements of apparel products. The racking is divided into three zones: a fast-moving goods area, a reserve storage area, and a temporary area for returns and exchanges, with clear traffic flows to prevent cross-interference. Upon project completion, the client’s warehousing costs were reduced by approximately 35%, while picking accuracy improved from 92% to 99.5%. The client’s project lead stated that this has been their most valuable infrastructure investment during their expansion in Vietnam.

Products Used

Heavy Duty RackingMezzanine Racking
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