How to Fit More Pallets in an Existing Warehouse?

Westbow Systems
16 hours ago
3 min read

When your warehouse starts feeling tight on space, expansion might seem like the only way forward. But there are often smarter, faster, and more cost-effective solutions, especially if you take a strategic look at how your space is being used.

At Westbow Systems, we help warehouses across Western Canada rethink space, not just fill it. Before you invest in a bigger building, explore how to fit more pallets into the warehouse you already have using the strategies below.

1. Use Your Vertical Space More Efficiently

A surprising number of warehouses underutilize their vertical real estate. By upgrading to taller pallet racking systems, you can significantly increase pallet capacity without changing your building footprint.

Studies show that extending racking vertically can increase capacity by 20–30%, as long as you account for building codes, sprinkler clearance, and equipment reach.

Need help maximizing your ceiling height? Request a vertical space assessment from our warehouse design team.

2. Switch to Narrow Aisle or Very Narrow Aisle (VNA) Layouts

Standard aisle widths are often wider than they need to be. By converting to narrow aisle (8–9 feet) or very narrow aisle (5–6 feet) racking, you can gain significant space for additional pallet positions.

This change does require specialized equipment like turret trucks or articulated forklifts, and careful planning to maintain throughput. But the space savings often justify the investment, especially in high-volume operations.

Curious if VNA racking fits your layout? Book a layout consultation with Westbow Systems.

3. Consider Double-Deep or Push-Back Racking

Two of the most effective high-density racking systems are:

Double-Deep Racking: Stores pallets two-deep, increasing capacity by 20–30%. Best for operations with large pallet counts per SKU and where selectivity is less critical.
Push-Back Racking: Allows 2–5 pallets to be stored in depth with easy front-face access. It boosts storage by up to 65% and works well in LIFO environments like general manufacturing or distribution.

Each has trade-offs in access and cost, but both offer excellent ROI when matched to the right inventory profile.

Not sure which high-density system is right for you? Talk to a Westbow Systems storage specialist for tailored recommendations.

4. Apply Dynamic Slotting and Inventory Profiling

Sometimes, the problem isn’t lack of space, it’s how that space is being used.

Dynamic slotting uses data on SKU velocity, size, and seasonality to place products in optimal locations. By prioritizing high-movement SKUs near access points and slotting slower movers higher or further back, you can reduce congestion, improve flow, and increase effective storage.

Slotting optimization can improve space efficiency by 10–20%, and save time on every pick.

Ready to unlock hidden space with smarter slotting? Ask us about slotting audits and WMS-integrated solutions.

5. Leverage Cross-Docking or Flow-Through Techniques

If you handle fast-moving inventory, cross-docking can reduce the need for pallet storage altogether. With this method, inbound goods are immediately moved to outbound staging or loading areas, bypassing long-term storage.

This approach isn’t right for every operation, but when used correctly, it can dramatically reduce storage pressure and improve throughput.

Explore whether cross-docking can reduce your storage load. Request a supply chain flow review with our team.

6. Install a Mezzanine Floor

Installing a mezzanine, a raised structure above ground-level operations, can unlock valuable cubic space. While commonly used for light parts, office space, or packaging areas, mezzanines can also be engineered for pallet storage using lightweight racking.

They’re ideal for facilities with high ceilings and segmented workflows, and a great alternative to expansion.

Want to add a second level to your warehouse? Get a custom mezzanine design quote from Westbow Systems.

7. Audit Your Space and Apply Lean Practices

Sometimes, the fastest way to create more space is to remove what doesn’t belong.

Regular space audits often reveal:

Dead stock that could be liquidated
Inefficient racking layouts
Misplaced SKUs
Obsolete materials taking up prime space

Layering in lean warehousing principles like 5S (Sort, Set in Order, Shine, Standardize, Sustain) ensures your warehouse stays optimized over time.

Looking for a leaner, more efficient warehouse? Schedule a lean audit walkthrough with one of our specialists.

Fit More, Spend Less, Move Smarter

Fitting more pallets into an existing warehouse is about designing smarter. Whether it’s rethinking your racking, optimizing your layout, or leveraging technology to fine-tune storage, there’s often untapped potential in your current space.

At Westbow Systems, we work alongside clients as a storage strategy partner, helping you evaluate, design, and implement solutions that improve efficiency, control costs, and scale with your growth.