Warehouse Infrastructure

Warehouse Infrastructure

Customized warehouse architecture offered by Intramega Global is meant to improve your storage capacity and increase efficiency. From pallet racking, shelving, mezzanine system, to automation system, our team thoroughly evaluates your space and processes to create a customized system that effortlessly interacts with your current operations. The outcome is a warehouse designed for efficiency, therefore releasing its maximum possibilities for best storage and simplified operations.

Solutions

Pallet Racking

Find the perfect fit pallet racking storage solution for your requirements. Pallet racking can be easily configured in a variety of ways based on your needs and pallet load, to ensure a functional and logical warehouse storage solution for you.

Selective Pallet Racking gives your warehouse staff unrestricted access to all pallets at any one moment. To meet your particular storage needs, the very flexible system can be built as single or double-depth racks. Designed to fit various kinds of pallets, mesh boxes, bins, etc., this form of racking system is meant to fit perfectly to your available area.

The Selective Pallet Racking offers the following benefits as standard:

  • Individual access to all pallets to full height of warehouse
  • Simple stock rotation achieved
  • Easy beam adjustment accommodates variable pallet heights
  • Compatible with many handling equipment styles
  • Conventional tolerance for floors when used to 10m high
  • Lower level pallets can be located on the floor (picking pallets)
  • Accessories available can accommodate every unit load type
  • Economical shelving beams can be added for low level picking
  • High average locations used 95%, for 100% accessibility, good stock rotation
  • Lifetime Warranty – Conditions apply

Double deep racking is a perfect choice for fast distribution of big single-SKU orders since warehouse staff can store goods up to four pallets deep. For companies with high volume of a small variety of items whose SKUs are kept in pallet groups prior to release, it is quite helpful. Unmatched access via dual pantograph or sliding fork attachments comes from the double entry shelves.

The double deep racking offers the following benefits as standard:

  • Storage density increased as rack aisle ratio changes from selective racking
  • 50% immediate accessibility with reasonable stock rotation
  • Good use of all available locations, typically above 90%
  • Safe and secure handling with the bottom pallet usually off ground
  • Ability to use double deep handling equipment for other tasks
  • Best used when each SKU has several pallets
  • Lifetime Warranty – Conditions apply

Narrow Aisle Pallet Racking is your ultimate space-saving option if your warehousing or storage floor space is limited. It gives your teams maximum storage capacity, and allows for quick order-picking and fast accessibility to every pallet.

It uses standard pallet racking with a twist: the aisles between the racks are significantly narrowed down, typically to less than 1.5 meters (5 feet) wide. This space saving can be as much as 40% compared to traditional pallet racking systems. VNA racking is ideal for warehouses with high volumes of palletized goods and limited floor space.

Narrow Aisle Pallet Racking offers the following features and benefits as standard:

  • Total and unrestricted accessibility to individual pallets
  • Optimum configuration for maximum storage, density and efficiency
  • Makes optimum use of any given floor area, storage space and warehouse height (up to 12m high)
  • Any additional costs offset by added value of improved space

Mobile Racking is a dynamic solution providing up to double the storage capacity in the same area, of conventional pallet racking. Offering technical superiority and total flexibility, Mobile Racking is suitable for every kind of stored goods, and has a wide range of accessories.

The electronically controlled Mobile Racking high-load racking system runs on in-ground rails and can carry bay loads of up to 24 tons at racking heights of up to 12 meters. While state-of-the-art sensor technology and variable control options ensure ease of operation and absolute safety.

Mobile Racking offers the following benefits as standard:

  • Save up to 50% of the space required by conventional pallet racking, and increase storage capacity by up to 80%
  • Cuts energy, operating and cleaning costs; allowing for a good ROI
  • 100% individual pallet access
  • Wide variety of accessories
  • Suitable for any kind of warehouse goods
  • Guaranteed operational safety of -30° C; ideal for use in cold-storage rooms
  • Latest PLC-technology for perfect support of optional functions, plus touch screen with clear graphical display for optimum visibility

Designed as a semi-automated, high-density storage system that best uses space in your warehouse, shuttle pallet racking is typical pallet racking with electrically driven shuttles running on rails within the channels. These remotely controlled shuttles load and retrieve pallets, therefore removing the need for forklifts to access small passageways.

This greatly enhances safety by lowering the danger of accidents and damage, therefore augmenting storage capacity. A flexible option for warehouses with high-turnover palletized goods, shuttle racking can be set up for either First-In- First-Out (FIFO) or Last-In- First-Out (LIFO) operation.

Using the Pallet Shuttle system offers the following benefits as standard:

  • Cost effective and time-saving; not requiring the use of forklifts
  • Low level of risks or damage to the equipment and operating staff
  • Fast and sustainable; automatically handles pallet picking and retrieval
  • Offers more effective, high-density storage
  • Can pick up, deposit and re-organize pallets with great precision
  • Operating temperature ST: 0°C to +45°C / BZ: -1°C to -30°C / Hybrid model can be used in both temperature ranges
  • Available in different models designed for various pallet configurations
  • Designed in accordance with the European Directive 2006/42/EG and DIN EN 15095

Drive-in Pallet Racking is an ideal solution for storing large quantities of similar or identical goods, it can free up to 90% of existing floor area compared to traditional or standard types. This racking system reduces aisle loading and unloading times, while still allowing for greater accessibility than block-stacking.

Drive-in Pallet Racking offers the following features and benefits as standard:

  • More storage per cubic metre than any other storage system
  • High density storage – maximising floor and storage space
  • Limited stock rotation – ideal for seasonal goods and chilled storage
  • Accessible by the FILO principle
  • Smooth pallet rails – for safe, snag-free load-bearing
  • Brightly coloured pallets help drivers position loads quickly and accurately

Pallet Flow Racking, or ‘Pallet Live Storage’ is ideal if you operate a First-in, First-out (FIFO) goods storage setup. With this system you can use up to 60% less space than if you were to use conventional pallet racking.

Our Pallet Flow system offers a dynamic storage solution with integrated conveyor modules to suit most pallet types and sizes. It’s well-suited for the drinks industry or as a buffer storage facility in manufacturing.

Pallets travel smoothly on full-width or twin-track rollers. While the front pallet is removed on the front side of the rack, the rear pallet is held back. Pallet movement is always safe and smooth thanks to automatic braking, along with a combined load guide and end stop unit.

Pallet Flow Racking offers the following features and benefits as standard:

  • Dedicated load and retrieval means only two forklift truck aisles are required
  • Uses up to 60% less floor space than conventional pallet racking
  • FIFO operation – for automatic stock rotation
  • Faster, more efficient warehouse picking speeds

Our Mezzanine Flooring Structures provide you with a cost-efficient way to create extra floor space in your existing buildings. Simple yet effective, you can combine the uprights and beams to form heavy duty, multi-functional structures.

The system includes high-quality stairways, strong railings and three different kinds of pallet gates to suit even the most complex of warehousing or storage requirements. Totally demountable and reusable, it’s a far more economical solution compared to concrete constructs.

Mezzanine Floor Structures offer the following features and benefits as standard:

  • Multifunctional for a variety of users
  • Up to 1000kg/m2
  • A span up to 10 meters
  • A more economical solution than concrete
  • Easy to erect in existing buildings
  • Light transparent (with steel grid floors)
  • Free-standing (no additional loads on building columns)
  • Minimal additional pressure on the foundation floor
  • All Mezzanine floor railings, stairs and pallet gates have a scratch-resistant, powder-coated finish, and meet all the strictest of European compliance and safety regulations.

With our Multi-tier Pallet Racking, you can create manual pick-lanes for your teams at various levels, by providing walkways built into the pallet racking structure.

Our Multi-tier Pallet Racking offers optimum use of space over that of traditional mezzanine flooring structures and layouts. This type of pallet racking structure creates a number of levels and walkways for storing and collecting goods – everything from cartons and boxes, to garment storage on hangers.

Multi-tier structures can either be installed directly from the floor or alternatively on top of a specially designed mezzanine structure – allowing for a multi-functional storage area below.

Multi-tier Pallet Racking offers the following features and benefits as standard:

  • Combines wooden, mesh, grating or steel shelves depending on requirements
  • Increased number of picking levels
  • Maximises use of the full height of the building
  • Optimises floor space
  • Allows order-picking on multiple levels
  • Can combine pallet storage and small goods storage
  • Removes the need for a mezzanine floor
  • Easily incorporates fire sprinkler and lighting systems
  • Extensive range of stairs, handrails and pallet gates

Unlike traditional forms of racking, push-back racking lets pallets be kept from 2 to 6 deep on either side of an aisle, therefore optimizing storage density. Push-back pallet racking allows you to mix single-lane selectivity with drive-in rack density. Push-back systems’ capacity to maximize the available space and fast material loading and unloading define its most crucial characteristics.

  • Possibility of offering both high-density and selective storage
  • Compared to a conventional selective rack, can provide up to 2x to 3x higher storage capacity.
  • The uprights of a push-back rack are less exposed to damage since forklifts do not enter the system; therefore, there is little to no maintenance needed for this structure.
  • Compatibility and adaptability with other adjustable pallet rack systems due of the high compaction and resistance of roller and shuttle systems at low temperatures; it’s an excellent choice for cold storage or freezing; the LIFO push-back racking structure has a safety mechanism for controlling and braking loads that reduces the risks in both the shuttle and roller systems, so ensuring safe operation.

Our Pallet Pull-Out Units let your teams move pallets back and forth like drawers, even with a full load up to 1000 kg. With such efficient storage, they can free up the excessive clearance distance needed above pallets.

The Pallet Pull-Out Unit saves both time and space to ensure an efficient working environment and ergonomic picking. By installing pull-out units in your pallet racking, the number of pallet and picking locations can be increased, while still taking up the same space as before.

What’s more, shorter operation distances allow for faster and more efficient picking, while at the same time freeing up valuable floor space.

Our Pallet Pull-out Units offer the following features and benefits as standard:

  • Increase storage capacity
  • Create space
  • Allow easy access
  • Increase picking rates

The Carton Flow Racking system is a fast and flexible solution for you to transport components to assembly stations without interruption. You can also easily adjust the shelves and wheels to ensure efficient movement of various sized packages.

The Carton Flow Racking system is flexible enough to allow for changing and evolving warehouse layouts, thanks to the fact that it can be built as a stationary unit, or supplied with lockable wheels.

Alternatively it could also be integrated into pallet racking on any lower levels, below bulk storage, for example.

The Carton Flow Picking Unit system offers the following benefits as standard:

  • Adjustable, ergonomic racks – for ultimate handler efficiency
  • Separate loading and unloading – so picking can be carried out uninterrupted on either side
  • High packing-density for carton storage – meaning more floor space
  • Reduces travel distances and picking times
  • Simple, fast installation
  • Straightforward, modular system

Combine the best of both worlds with a pocket dense storage system integrated into your pallet racking. Imagine sturdy drawers on tracks lining the first level, perfect for organizing and storing all your smaller, frequently accessed items. The upper level functions like traditional pallet racking, accommodating your bulkier palletized goods. This clever combo maximizes space utilization and keeps your workflow smooth by offering easy access to everything you need.

  • 40% More space
    The Storeganizer pockets are easily installed in any type of pallet rack around the world, independently of manufacturer and/or beam type.
  • 42% Reduction in travel time
    An impartial study showed 40% savings in usable warehouse storage space after introducing warehouse storage system Storeganizer, allowing order pickers to travel 42% less distance when retrieving product versus conventional rack-and-shelf systems.
  • 26%+ Order picking efficiency
    Storeganizer is made of lightweight industrial fabric yet can hold 220 pounds (100 kg) per column and is guaranteed for up to 10 years.

Shelving System

Intramega Global continues beyond palletized storage. Our shelf systems are made to maximize space use for every non-palletized item you might have. We provide a range of shelf solutions to exactly fit your particular requirements, so guaranteeing quick access and effective organization for a better flow of business.

For your warehouse, our medium duty shelving is essentially the workhorse. Boxes, containers, tools, and even equipment—all kinds of items not found on pallets—are ideal for keeping on these robust and dependable shelves. Although they can handle a decent weight and are made to last, they are also reasonably priced, which makes them a wonderful alternative for companies having various storage requirements. In the long term, medium duty shelving saves time by allowing you to maximize all the space in your warehouse and maintain the organization of your valuable items, therefore facilitating their quick access.

The Medium Span offers the following features and benefits as standard:

  • Easy assembly and disassembly
  • Fully galvanized and durable
  • Customisable shelving profiles for extra strength and stability for shelf supports
  • No loose parts, and no sharp edges
  • Shelf supports with recessed labels and barcodes
  • Extensive range of accessories

Light duty shelving is the best option for items you want to view clearly or those you need to grab often. These shelves are flexible and meet your particular need by means of adjustment.

For lighter goods like files, binders, or smaller parts, they’re also an excellent choice as they’re not as heavy-duty as the medium shelf.

Light duty shelves allow you to use all of your space without sacrificing accessibility to what you need. This helps you to keep track of your inventory and choose objects more quickly.

For warehouses, mobile shelves represent a space-saving breakthrough. Imagine rows of robust shelves on wheels, gliding easily along rails. This clever design releases a startling amount of additional space by eliminating the requirement for fixed aisles. The advantages are significant: the same footprint allows you to store up to twice the inventory than on conventional static shelves.

While customizing lets you better organize and access each item, minimized wasted space translates into much speedier picking times. For warehouses, manufacturers, stores, and archives, mobile shelving’s adaptability makes it perfect.