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Case Study: Mezzanine Racking System

Dubai Imports Limited

Flexible mezzanine racking engineered to accommodate diverse product ranges within space constraints

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PROJECT OVERVIEW

Palletower helped Dubai Imports transform a new Southall facility into a more efficient storage environment, creating a flexible mezzanine racking layout for a wide variety of products.

Project Type:

Mezzanine Racking System

Industry:

Instore Retail & E-commerce

Requirement:

Complex Multi-Product Storage

The brief

Dubai Imports required an efficient racking system for a new facility with a 25 x 45 metre mezzanine. The site needed to store a varied product range, from fine dining kitchen equipment and high-value goods to mattresses, furniture, seasonal items and florist supplies. 

The company had worked with Palletower for more than five years, so the project built on an existing relationship and a clear understanding of the client’s operational needs. 

The challenge 

The original racking layout clashed with the existing lighting, which meant the design needed to be reconsidered before installation. The building also contained a number of small and awkward spaces, requiring different racking types to be used side by side. 

Weight distribution across the mezzanine was a key consideration, particularly because the stored items varied so widely in size and weight. Beam heights also had to allow for furniture storage with additional space above. 

Access added another layer of complexity. The mezzanine could only be reached by a small lift and a spiral staircase, meaning longer components had to be carefully manoeuvred into position. 

PROJECT DETAILS

Palletower’s solution 

Palletower revised the racking direction to improve lighting coverage and make better use of the available space. The layout was then planned around the client’s inventory, mezzanine constraints and day-to-day handling requirements. 

Because the warehouse footprint was limited, installation had to be phased. Existing stock was moved, one section of racking was installed, and items were then repopulated before work moved on to the next area. 

When missing components from the manufacturer threatened to delay the project, Palletower used its supplier relationship to reduce the replacement delivery time from eight weeks to three. 

The result 

The finished system delivered a flexible, carefully planned mezzanine storage solution for a highly varied inventory. Planning began in June 2022, client meetings took place from April 2023, and the project was completed in December 2023. 

Key outcomes 

  • Improved storage layout for a complex product range 
  • Better lighting coverage through revised rack direction 
  • Multiple rack types integrated within one mezzanine area 
  • Phased installation around stock already on site 
  • Reduced project delay through faster supplier coordination 

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Cargopak Ltd are now part of Palletower, Europe's largest providers of storage and logistic equipment.