High-Density Storage Meets Automation: How DP World fit 16 million units into existing warehouse footprint

By combining Storeganizer high-density textile storage with autonomous mobile robots (AMRs) you can condense thousands of pick locations into a fraction of the floor space creating the concentrated pick density needed for robotics systems like Locus to run at peak efficiency.

George Gailey, Site Manager of DP World (UK) found that Storeganizer was the ideal solution to increase SKU density without needing an expansion. “I would highly recommend Storeganizer, especially for its flexibility across all warehouse operations." 

DP World (UK) is the home of Utopia Music with 70% of UK music distribution coming from this facility. This is a 270,000 ft warehouse with a 50,000 ft mezzanine receiving 65,000 SKU's, accumulating to 16 million units, so from a density point of view Storganizer made sense.

The primary challenge for DP World was to optimise storage density within their existing footprint to handle their extensive inventory and demanding distribution schedule. With 16 million units to manage, finding a way to fit as many products as possible into the available space was critical. Additionally, the solution needed to enhance operational flexibility to scale quickly based on fluctuating demand, and to improve efficiency by reducing the extensive walking required for order picking.

By combining Storeganizer high-density textile storage with autonomous mobile robots (AMRs), DP World was able to condense thousands of pick locations into a fraction of the floor space creating the concentrated pick density needed for robotics systems like Locus to run at peak efficiency.

To address their challenges, DP World implemented Storeganizer. George Gailey explained, "From a density point of view, that was why we looked at Storeganizer. We had to fit in as many products as possible into that footprint. Storeganizer gives us that density. And it allows us flexibility as well." Storeganizer significantly increased storage density by providing 105,000 locations condensed into one and a half miles of Storeganizer bays, effectively utilising vertical space. This innovative storage system enabled DP World to maximise their storage. 

To complement Storeganizer, DP World also integrated Locus Robotics into their operations. "Having the four and a half miles of pickfaces through Storeganizer meant that we needed to complement that with something, rather than people doing all the mileage. So we've complemented that with Locus Robotics," Gailey noted. The addition of 83 robots working in conjunction with Storeganizer reduced walking time for employees, significantly boosting efficiency. This combination of advanced storage solutions and automation allowed DP World to streamline their processes, making rapid scalability and timely product distribution achievable. The addition of 83 robots working in conjunction with Storeganizer reduced walking time for employees, significantly boosting efficiency. A perfect combination of advanced storage solutions and automation.

The installation of Storeganizer at DP World was a simple process. "The installation of Storeganizer was seamless. We didn't start until May 2023 and we went live in August 2023," Gailey recounted. This swift and efficient installation ensured minimal disruption to ongoing operations and allowed DP World to quickly reap the benefits of the new systems. Storeganizer created the compact pick density; the robots eliminated the human walking mileage. This was installed seamlessly without shutting down operations.

The integration of Storeganizer and Locus Robotics led to substantial improvements in DP World’s operational efficiency and storage capacity. Gailey highlighted the benefits, stating, “Storeganizer working with the automation that we have makes everything far more flexible for us. From a headcount model and point of view, from a timeline point of view, everything becomes far more achievable.” The enhanced density provided by Storeganizer allowed the facility to handle a larger volume of inventory within the same footprint, while the automation reduced walking time and improved worker efficiency. The overall result was a more flexible, scalable, and efficient operation capable of meeting strict deadlines and handling the vast volume of products.

DP World UK ‘s experience with Storeganizer can be linked back to local operational challenges here in Australia and New Zealand. Industrial real estate and warehouse lease rates remain at historic highs across major Australian hubs and operators cannot simply rent more square metres. Robotics provides the speed, but Storeganizer provides the density that makes robotics viable in existing footprints. Reduced travel time means smaller, higher-performing teams that are less susceptible to labour shortages. Plus moving between bulk B2B shipments and individual pick-and-pack eCommerce orders requires adaptable infrastructure, not static steel shelving. Sprawling traditional static shelving can take away available floor space and force pickers to walk excessive distances daily. Storeganizer high density storage paired with robotics can transform order picking into a more efficient process.

Contact the MarketKnowledge team to arrange a warehouse storage assessment and see for yourself how many pick locations your standard pallet bays could hold.