The challenge
As one of the UK's leading fashion retailers, New Look operates hundreds of stores across the country and relies on an efficient distribution network to keep products flowing to its retail locations.
At its distribution centre in Northern England, New Look needed a high-density storage solution capable of handling a large variety of product sizes while maximizing picking capacity within a limited footprint. The challenge was not only to increase storage density, but also to create a more efficient picking environment that would reduce operator travel time, improve productivity, and support fast-moving fashion items without requiring additional warehouse space. For this reason, New Look partnered with Pickfaces®, Storeganizer’s UK distributor.
An additional complexity was the installation location on top of a mezzanine floor, which required careful engineering to ensure the structure could safely support the new storage system.
The solution
Working closely with New Look, Pickfaces® designed and installed a customized Storeganizer solution tailored to the retailer's operational requirements.
The installation consisted of:
- 120 bays of pallet racking equipped with Storeganizer
- More than 780 storage locations per bay
- A unique layout combining small pick locations in the front and middle rows with larger pick locations at the rear, providing flexibility for different product sizes.
- Timber spreader plates installed beneath the system to distribute loads evenly across the mezzanine floor structure and ensure safe operation.
The solution was specifically designed to integrate seamlessly into New Look's existing warehouse processes and infrastructure.
Despite the scale of the project, the installation of the racking, timber spreader system, and Storeganizer solution was completed in three weeks.
The outcome
The customized Storeganizer installation delivered exceptional storage density while maintaining operational flexibility. By maximizing storage density within its existing footprint, New Look significantly increased picking capacity while retaining the flexibility required for a diverse fashion product range.
The high-density solution also improved picking efficiency by bringing more inventory closer to operators, reducing walking distances and enabling faster order fulfillment. By consolidating a large number of SKUs into a compact footprint, New Look was able to optimize space utilization, improve workflow efficiency, and achieve a strong return on investment without the need for costly warehouse expansion.
The project demonstrates how high-density storage solutions can unlock the full potential of existing warehouse infrastructure while supporting productivity improvements, operational scalability, and future growth.
The key results
· Over 110,000 individual pick locations created
· Less than 400 m² (4,000 sq. ft.) of floor space utilized
· Significant increase in storage density and picking capacity
· Reduced operator travel distances and improved pick efficiency
· Faster order fulfillment through optimized SKU accessibility
· Flexible storage for multiple product sizes
· Optimized use of existing warehouse infrastructure
· Strong return on investment through better space utilization and productivity gains
· Safe installation on mezzanine flooring through engineered load distribution
· Full implementation completed in under two weeks
About Pickfaces®
Pickfaces® is an innovation focused, warehouse and industrial solutions partner. We work together with warehouses and project teams to deliver efficient, operational solutions that deliver substantial returns for businesses striving for excellence and efficiency.
www.pickfaces.com
