As production volumes continued to grow, Leekes Ltd required a more efficient approach to storing finished goods for their customer Hensol Castle Distillery. The existing operation relied upon a 21,000 sq. ft bonded warehouse — providing sufficient capacity but representing a significant operational expense far greater than necessary.
The challenge: how could the business maintain the same storage capacity while reducing warehouse space by more than two-thirds?
The project also needed to deliver on five key objectives:
Reduce Operational Costs
Lower warehouse rental and associated operating expenses to improve financial performance.
Improve Space Utilisation
Maximise the cubic storage volume available within the reduced warehouse footprint.
Streamline Operations
Reduce unnecessary forklift travel and improve pallet handling efficiency throughout the facility.
Improve Safety
Minimise forklift interaction with racking to reduce the risk of accidental rack damage and injury.
Create a Scalable Platform
Deliver a solution capable of supporting future growth in production volumes and inventory levels.
The solution: Spacemaker DualAxis Pro® High-Density Storage System.
To achieve the required storage density, Leekes implemented, with advice from HFT (Hereford Forklifts), a high-density shuttle storage solution based around the Spacemaker DualAxis Pro® pallet shuttle system. Rather than forklifts entering storage lanes, pallets are placed onto the shuttle at the rack entrance. The shuttle then automatically transports pallets to the correct storage location within the lane — maximising density while reducing forklift movement and improving safety.
Solution Components
•Spacemaker DualAxis Pro® Pallet Shuttle
•High-Density Deep-Lane Racking
•Semi-Automated Pallet Transfer
•Optimised Warehouse Layout
The Result: A highly efficient warehouse solution capable of storing large volumes of palletised product within a dramatically reduced footprint — without compromising operational performance or stock accessibility.
The Spacemaker DualAxis Pro® solution enabled Leekes to successfully transform warehouse utilisation, reducing space requirements by more than two-thirds while maintaining full storage capacity and improving overall operational performance. The project demonstrates how modern pallet shuttle technology can help manufacturers and distributors unlock significant efficiencies from existing warehouse operations without compromising productivity or accessibility.
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