Asco Foods, one of Britain’s leading importers and wholesalers of South-East Asian grocery and frozen lines, has completed a swift relocation to a 51,000 ft² distribution centre in Thame, Oxfordshire. Delivered in partnership with AR Racking and specialist integrator STS Storage Systems, the project equips the building with more than 5,500 pallet locations and enables seamless handling of both ambient and temperature-controlled stock — laying solid foundations for the company’s next phase of expansion.
The growth challenge
Demand for Asco’s diverse portfolio had long out-stripped the capacity of its previous warehouse. Facing rising overflow costs and ever tighter service-level promises, the business resolved to move — but with two critical constraints. First, the change-over had to be completed on an aggressive timetable, keeping customer deliveries on track throughout. Second, whatever went into the new shed had to provide headroom for the company’s continuing growth while maintaining the flexibility required by a fast-moving ethnic food range, much of which must be stored at controlled temperatures.
A technical solution built around flexibility
After detailed analysis, AR Racking prescribed an Adjustable Pallet Racking (APR) layout rising to 11.5 metres clear height.
APR’s simple beam-and-frame design allows shelf levels to be repositioned quickly as SKU profiles evolve, giving Asco an adaptable structure without the cost or complexity of deeper automation. The scheme was configured around the industry-standard 1,000 × 1,200 mm pallet footprint, applied uniformly across ambient and chilled zones to keep aisle widths and mechanical-handling equipment identical throughout the site.
Steelwork was pre-fabricated in AR Racking’s Bilbao plant, with structural calculations carried out in advance so that the on-site team could concentrate on a fast, clean install. The result is a dense, high-rise storage block that maximises cubic utilisation while still offering direct access to every pallet—a must when case sizes, rotation rates and best-before dates differ widely across the range.
Two-phase implementation keeps product flowing
Speed of delivery was paramount, so the partners divided the build into two tightly sequenced phases completed in January and May. The first phase erected a core section of racking to accept inbound goods immediately, allowing picking operations to begin at Thame while dispatches continued from the former site. Phase two then extended the structure to its full footprint, slotting into place without interrupting live traffic. Close daily coordination between AR Racking’s engineering team and STS Storage Systems ensured the programme stayed on schedule and within budget.
Results that speak for themselves
“Our growth demanded that we act quickly yet strategically,” says Sunny Chadha, Director at Asco Foods. “The storage solution has let us relocate smoothly, improve inventory visibility and make the most of every cubic metre of our new warehouse.”
Gonzalo Crovetto, Project Manager at AR Racking, highlights the collaborative engineering approach: “We adapted the system precisely to Asco’s technical and timing requirements; prefabrication and meticulous planning were key to meeting the deadline.”
For Richard Tyrell, Project Lead at STS Storage Systems, the project underlines the value of early engagement: “Understanding the customer’s challenges in depth allowed us to translate them into a flexible, efficient and high-quality installation.”
Positioned for tomorrow
With a modern, scalable storage platform now in place, Asco Foods is ideally positioned to widen its product offering and strengthen its UK service network. The Thame site provides the capacity and versatility to absorb future volume surges, while the racking’s adjustability means the layout can evolve as the range does — proof that the right storage choice today can pay dividends for years to come.
Get in touch
To learn more about this project or discover how AR Racking can optimise your warehouse, email infor@ar-racking.com or visit www.ar-racking.com.
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