Lecico Bathrooms ‑ Pallet Shuttle Systems

The Challenge

Lecico Bathrooms stored pallets of ceramic bathroom products by block-stacking them three or four high, without using racking. Although block-stacking is a space-efficient system, moisture in the air softened the cardboard packaging, causing stacks to lean or fall, creating a health and safety risk.

The challenge was to create a safer system without losing storage capacity. The new layout also needed to account for forklift routes and travel distances, with the aim of improving logistical efficiency.

The Solution

The Oakway team analysed Lecico’s SKU profiles, product throughput, forklift routes and travel distances to assess current and forecast operational requirements. This analysis informed a racking design that fitted within the existing block-stacking footprint while maintaining storage capacity and improving safety.

The chosen solution was a semi-automated, high-density 2-way shuttle system, split into two zones to match Lecico’s current and forecast throughput requirements. Pallets were limited to no more than two high, reducing the risk of collapse from tall, unstable stacks, while the shuttle made efficient use of the available storage locations.