Are you struggling to find a budget-friendly way to accommodate your growing inventory in your warehouse? Perhaps all you need is a bulk storage warehouse and its space-saving advantages. With bulk storage, you don’t need any complicated systems to maximise space, reduce costs, or keep operations running smoothly. Let’s dive into detail!
1) What is Bulk Storage
Bulk storage refers to storing particular items in large quantities in the same area. This technique is also referred to as floor stacking. It doesn’t involve bulk storage racking or shelves; you directly place goods on the floor of the warehouse or put them on top of each other on pallets. For optimum results, this technique should be used with items that aren’t fragile.
You will often notice bulk storage on boxes, containers, sacks, and drums. It also reduces the need for expensive storage systems. If your business deals with the rapid (high-volume) inflow and outflow of goods, bulk storage is definitely the way to go.
But it wouldn’t be optimal for keeping numerous sensitive items. You may also find trouble accessing particular items right away.
2) Types of Bulk Storage Methods
People use different methods for bulk storage depending on the goods, the volume, and how the goods need to be organised. Some of the common methods of bulk storage include:
i) Block Stacking
Block stacking is regarded as one of the most organised structures of storage. You stack merchandise directly on top of each other in blocks or rows. While it can be done without pallets, it is more convenient to stack items that are placed on pallets to a safe height.
Keep in mind that this only works if each item in the stack is identical. It saves space and is easy to manage if you’re dealing with large amounts of the same product.
ii) Floor Stacking
Nothing can be easier than stacking in the form of floor stacking, where goods are put on the floor in a horizontal manner, without thinking of what comes on top of what. Floor stacking makes sense in the case of non-stackable heavy items, fragile goods or any item that is non-stackable.
Other than space and equipment to move the goods, there are no additional requirements.
iii) Liquid Bulk Storage
Chemicals, oils and grains are usually stored in tanks, silos or large containers. These storage structures are best for bulk storage, designed to hold liquids or free-flowing solids. The food industry, agriculture, and especially manufacturing are some of the leading users of this type of storage.
iv) Bag And Sack Storage
Storage of items such as rice, flour, or cement, which are packed in sacks or bags, can be done using block stacking or bins. It depends on how much support or protection the product requires.
v) Bulk Containers
They are mostly used in shipping and manufacturing. These are large, reusable containers used to hold big amounts of loose or packaged goods.
Each method suits different types of goods. When choosing a bulk storage method, think about the weight, shape, and handling needs of your products. Choosing the proper technique facilitates optimised space usage and efficient stock management.
3) Advantages of Bulk Storage
Bulk storage has many advantages, especially when managing large volumes of a single product. It optimises the structure of your warehouse and decreases the expense. Here is a list of notable advantages:
+ Space Efficiency: Storage in bulk is suitable for many warehouses because it enables economical utilisation of space. By making vertical stacks of items, there is less need for extra shelving and aisles. More products can be stored in the same area as before.
+ Cost Efficient: Your setup costs are lower since bulk storage does not require costly racks or shelves. There is also a saving on maintenance since bulk storage has less equipment to manage and repair. This makes bulk storage ideal if you are operating on a limited budget.
+ Easy Setup: There are no complex systems or special tools needed. Open floor space alongside pallets and forklifts is all that is needed for most bulk storage setups. There are few training requirements needed to start using it right away.
+ Quicker Handling: Bulk goods can be loaded and unloaded quicker, as large amounts can be moved at once. This helps increase the speed at which your warehouse operates. So, it is important for fast-moving or seasonal items.
+ Helpful during reorganising: Bulk storage enables you to change your space as needed. As inventory fluctuates, goods can be moved or the layout adjusted, making this helpful for staying organised during busy times.
+ Great for Homogeneous Products: If your business deals with uniform products such as packaged goods or materials in drums, bulk storage makes it simple to keep everything together and easy to locate.
In general, bulk storage offers the best methods to save on time, space, and funds while maintaining ease in operations and efficiency.
4) Disadvantages of Bulk Storage
There are multiple drawbacks of bulk storage, and knowing them can help you make a decision for your warehouse.
– Limited Accessibility: Accessing specific goods within bulk storage is one of the hardest challenges. In block stacking, you frequently need to lift or remove other products to get the one you need. If you require multiple items throughout the day, this can disrupt the flow of your operations and can be especially problematic for high-frequency pick customers.
– Difficult Inventory Management: Bulk storage makes it challenging to track and manage your inventory. Methods like FIFO (First In, First Out) or FEFO (First Expired, First Out) are hard with bulk storage due to accessibility issues with lower stacks. This might lead to unused older stock stuck in storage for a longer time than needed, leading to wastage.
– Risk of Product Damage: Without care, putting goods on top of each other can cause damage. Bottom items might get crushed by unstable or heavy stacks, leading some to get tumbled over. Goods that are weak or sensitive are particularly susceptible to this.
– Not The Best Fit for All Products: Best suited for just storable goods. It does not work well with fragile, perishable, or even irregularly shaped items. These types of goods may need special handling, unit temperature control or protection, which bulk storage does not provide.
– Risks to Safety: If not done correctly, improper stacking can lead to safety risks for your workers. The goods shopped in bulk also suffer injuries and damages. Stacking goods should be done carefully and must follow strict safety guidelines.
– Space Misallocation for Mixed Products: If your inventories have too many different products, bulk storage might lose its purpose. Items are grouped in large blocks, which can make orderly mixed or varied stocks more difficult to organise.
In simpler terms, bulk storage cannot accommodate every situation. Make sure to assess the product types, frequency of storage access, and safety before settling on this storage method.
5) Comparison: Bulk Storage vs. Rack Storage
In the process of product storage, you often have to decide between bulk storage and rack storage. Both methods possess unique characteristics to fulfil diverse warehouse needs. Let’s systematically list them out for better understanding.
- Spatial Efficiency
Bulk Storage: Goods are stored in bulk directly on pallets or the floor, maximising vertical space. It saves floor space by reducing aisle space, but can become hard to manage if stacks get too high.
Rack Storage: Organises goods in both vertical and horizontal directions using shelves or racks. Products are stored on racks or shelves, and aisles are required between racks, so it may use more floor space but offers better visibility and access.
- Cost
Bulk Storage: Lower setup cost because no racks or shelving systems are needed. Maintenance is also lower.
Rack Storage: Higher initial cost due to purchasing and installing racks. Maintenance and possible automation add to expenses.
- Access
Bulk Storage: Limited accessibility. Items in the middle or the bottom of stacks are more difficult to reach, which speeds up picking.
Rack Storage: High accessibility. Each product has a specific spot on racks so that picking is quick and easy.
- Inventory Tracking
Bulk Storage: Difficult to manage inventory precisely. Methods like FIFO or FEFO will be more difficult to put in place due to the stacked layout.
Rack Storage: Easier inventory control with organised, separate storage spots that allow effective FIFO and FEFO practices.
- Flexibility
Bulk Storage: Very flexible. Layout changes can be made at a moment’s notice to accommodate changes in inventory levels.
Rack Storage: Less flexible. Rearranging the racks takes some time and effort after they have been set up.
- Product Suitability
Bulk Storage: Best used for large quantities of uniform and durable products that are safe to stack.
Rack Storage: Appropriate for varied inventory, fragile items, or products needing special care.
Feature | Bulk Storage | Rack Storage |
| Space Utilization | High (vertical stacking, fewer aisles) | Moderate (requires aisles for racks) |
| Cost | Low setup and maintenance | Higher initial and upkeep cost |
| Accessibility | Limited (hard to reach items in stacks) | Easy (each item has a dedicated spot) |
| Inventory Control | Difficult (poor for FIFO/FEFO) | Easy to manage (supports FIFO/FEFO) |
| Flexibility | Very flexible, easy to rearrange | Less flexible, fixed racks |
| Product Type | Uniform, durable, stackable goods | Varied or sensitive products |
6) Common Use Cases for Bulk Storage
When it comes to storing items in large quantities, bulk storage is the most effective solution. Saving space and cost makes bulk storage the best option for certain situations. Here are some ideal scenarios best suited for bulk storage:
- Fast-Moving Products: If you deal with products that have a fast turnover, bulk storage can be used to store packaged foods or beverages in large amounts. With bulk storage, you can easily load and unload goods based on the demand.
- Uniform Items: Bulk storage is best if your inventory consists of the same items, such as boxes, drums, or sacks. With bulk storage, you can stack and organise these containers without thinking about wasting space.
- Seasonal Stock: Mass storage is excellent for seasonal-specific products that are only used at certain periods throughout the year. These items can be kept in large amounts and protected until they are ready to be sold or moved.
- Durable Goods: Bulk storage is ideal for sturdy items that can be stacked and bear rough treatment, such as building materials and canned goods, as well as non-fragile goods. It is not suitable for fragile products.
- Short-Term Storage Solutions: Well, if your storage needs are for the short term, bulk storage allows quick setup and rearrangement. This is useful during busy special projects or during seasons.
- Budget-Friendly Warehousing: Bulk storage is more economical to set up compared to other options, making it ideal for businesses that are looking to lessen the costs without losing storage space.
Great! Bulk storage warehouse is best if you have to work with large quantities of the same type of durable good, especially when needing to access them quickly at a low cost. This type of storage system will help you maintain organisation and efficiency of warehouse for seasonal and fast-moving products.
7) Factors to Consider While Implementing Bulk Storage
Okay, when choosing to apply bulk storage in a warehouse, there are a number of key factors, if taken into account, you can use the available space in a good manner while maintaining working efficiency.
- Product Type: What is the nature of the products you want to store? You know bulk storage is most suitable when dealing with stackable, storable, and uniform goods.
- Weight and Size: What is the weight and the size of your goods? Heavy goods will need a strong floor, and stacking them will have to be done very carefullly to prevent any type of damage. To add, large or oddly shaped goods may prove to be difficult to stack securely.
- Warehouse Space: Pay attention to the layout of your warehouse. Consider also the height of the ceiling. The bulk storage method takes benefit of vertical space where the ceiling height is generous. Well, it is possible to stack products higher, therefore saving floor space.
- Accessibility Needs: How often does one need to access the various products? Bulk storage limits quick access to pick up the items located at the base of the stacks, which means it is most suited for goods that are not regularly needed.
- Equipment Used for Handling: Forklifts or pallet jacks will be required in order to move and stack the goods in a safe manner. Make sure that the right equipment is available, as well as trained staff to operate the machinery.
- Ensure Safety: The stacking of products requires a lot more care than what is provided, as it may lead to possible accidents. Implement stacking heights and weight limits along with proper training for employees.
- Keep record: Create important records of the items along with organised labels for streamlined access to avoid confusion and loss of stock.
With all of the above considerations taken into account, implementing bulk storage can save a lot of space and costs in the warehouse.
8) Conclusion
Bulk storage offers a good way to store uniform-shaped and sized products in bulk at a low price. However, it only works for sturdy items that you do not have to access frequently. Alright! Organising your warehouse becomes easy when the type of product kept in storage is taken into consideration.
If you are looking for solutions for bulk storage in your warehouse and need the correct equipment to do it safely, efficiently, and cost-effectively, Mracking is here to help. We offer all types of storage equipment, from simple pallet racks to custom bulk storage systems, tailored to your needs. With our expert guidance and range of storage products, there’s a way to organise your warehouse without exceeding your budget.
