5 Tips for Building a Warehouse Today That Will Be Ready for Tomorrow

New technology has completely changed the warehouse and cold storage industry. Same-day delivery, e-commerce and more have forced warehouse operations to modify distribution and delivery processes.

Every day, warehouse operations enhance their systems, now digitally outfitted with game-changing WMS software and tools that increase efficiency and effectiveness.

Inventory is stored, tracked, picked, and delivered much differently today than it was even just a decade ago, resulting in warehouse owners needing to update existing facilities.

And if you’re building a facility from the ground up, the stakes have never been higher.

What are the most important considerations you should address along the way? From the initial planning stages all the way through opening your warehouse doors, we have the top 5 tips you should focus on while building your new warehouse.

Contents

• Location, location, location
• e-Commerce
• Accommodate the Robots
• Invest in 3D Modeling
• Ask the Experts
• Frequently Asked Questions

Contents

• Location, location, location
• e-Commerce
• Accommodate the Robots
• Invest in 3D Modeling
• Ask the Experts
• Frequently Asked Questions

Contents

• Location, location, location
• e-Commerce
• Accommodate the Robots
• Invest in 3D Modeling
• Ask the Experts
• Frequently Asked Questions

Contents

• Location, location, location
• e-Commerce
• Accommodate the Robots
• Invest in 3D Modeling
• Ask the Experts
• Plan for Scalable Storage Systems
• Build for Operational Resilience and Risk Management
• Frequently Asked Questions

Location, location, location

Meet customer demands efficiently and quickly by carefully selecting a location. The site you pick matters more than you may think. At one time, companies built warehouses in rural areas because land was cheaper. But today there is greater demand (and fierce competition) for next-day or same-day shipping. That makes it increasingly difficult to be off the beaten path. Now more than ever, it’s essential to be close to the population, and that often means in the heart of a city. Amazon is a prime example of where we may be heading: Cities are competing to have the eCommerce giant open locations within their city-limits. 

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e-Commerce

Traditional warehouse layouts once allowed for easy distribution for brick-and-mortar stores. Cases of products were picked, packed, shipped, and delivered using pallets and trucks. But e-commerce has drastically changed this dynamic. Now, with small-volume ordering and fast, on-time delivery as the primary focus, it’s more the norm to have to pick items individually. The result? A complete overhaul of the physical space of warehouses. Warehouses now need to be designed to reflect new and different demands while allowing for the easy processing of both picking and of handling any returned items.

Accommodate the Robots

As automation continues to emerge in warehouse spaces, any new or revamped warehouse builds need to be designed to allow for the current or future use of robotics.

• Automated Guided -Vehicle (AGV) pathways
• Vertical space that can better-accommodate transportable shelving
• Automated picking and packing robotic arms
• High-speed conveyor systems
• Room for future automated tools
• Temperature control

To maximize the potential of your new space, it’s wise to optimize your warehouse to include space for automated technologies, even if you won’t be using them right away. Planning now so you can incorporate new technologies and features as you grow is just plain smart. Because the last thing you want is to discover your new facility lacks the dimensions needed to eventually get your robotics up and running.

Invest in 3D Modeling

3D modeling helps you identify any potential (perhaps costly) bottlenecks that result once humans and robotics are trying to work together. A skilled and experienced warehouse designer will be able to figure out how to maximize vertical space while keeping dead space at a minimum. Modeling may also be able to demonstrate fly-through videos to help detect potential collisions so you can modify plans before they impact your operation.

Ask the Experts

Warehouse design has changed. Large distribution centers are moving from single channel to multichannel inventories and smaller warehouses while automating their operations. Let an expert in the industry help you. They can assess your current system and look for ways to improve. For example, design experts can ensure you eliminate inefficient uses of space.

Ready to upgrade or move your warehouse operation? One of the final (and most important) steps of the process is ensuring you have a WMS that is efficient and effective, so all your efforts can pay off in a cost-effective operation that gets you results!

If you would like to improve the performance of your current warehousing operation, contact us for a Competitive Replacement Plan specifically designed for your needs.

Reach out to Argos today to learn more about how the right solutions can improve all aspects of your business, from warehouse inventory management to value-add transactions and more.

Plan for Scalable Storage Systems

Future-ready warehouses require storage systems that can adapt to changing inventory demands and product mix variations. Modern facilities must accommodate both high-velocity SKUs and seasonal fluctuations without requiring complete infrastructure overhauls.

Modular racking systems provide the flexibility to reconfigure storage layouts as business needs evolve. These systems allow warehouse operators to adjust shelf heights, aisle widths, and storage densities without major construction projects. Consider implementing:

• Adjustable pallet racking with variable beam positions
• Mobile racking systems that maximize space utilization
• Mezzanine platforms for additional storage levels
• Cantilever racks for long or irregularly shaped items

Design your warehouse with expansion zones — designated areas where additional storage can be added as operations grow. Plan electrical and data infrastructure to support future expansion without requiring costly retrofits. This includes positioning power distribution panels and network access points to serve both current and planned storage areas.

Optimize for SKU Velocity Management

Incorporate zones for different product velocities into your initial design. Fast-moving items should be positioned closest to shipping areas, while slower-moving inventory can be stored in less accessible locations. Plan for at least 20% of your storage capacity to be easily reconfigurable to accommodate shifts in product velocity over time.

Build for Operational Resilience and Risk Management

Modern warehouses face increasing risks from supply chain disruptions, extreme weather events, and cybersecurity threats. Building operational resilience into your facility design protects against costly downtime and ensures business continuity.

Redundant systems and backup infrastructure are essential components of a future-ready warehouse. Install duplicate power systems, including uninterruptible power supplies (UPS) and emergency generators, to maintain operations during outages. Design your network infrastructure with multiple internet service providers and backup communication systems.

Climate control systems should include:

• Multiple HVAC units to prevent single points of failure
• Temperature monitoring systems with real-time alerts
• Backup cooling systems for temperature-sensitive inventory
• Energy-efficient insulation to reduce operational costs

Implement Advanced Security Measures

Physical and digital security must be integrated from the construction phase. Install comprehensive surveillance systems with AI-powered analytics, access control systems that integrate with your WMS, and secure server rooms with environmental controls. Plan for segregated network zones to isolate critical systems from general warehouse operations.

Consider natural disaster preparedness in your structural design, including flood-resistant electrical systems, wind-rated doors and roofing, and fire suppression systems that protect both inventory and automation equipment. These investments reduce insurance costs and minimize operational disruptions.

Frequently Asked Questions

What factors should I consider when planning a new warehouse building?

Consider current and projected storage requirements, operational workflows, and growth plans. Evaluate ceiling height needs, floor load capacity, dock door quantity, and column spacing for your operations. Plan for technology infrastructure, climate control if needed, and adequate power capacity. Location factors include labor availability, transportation access, and proximity to customers or suppliers.

How do I design a warehouse for future flexibility?

Build in excess capacity for growth rather than fitting current needs exactly. Design clear span areas without excessive columns that limit layout options. Install robust electrical and data infrastructure that can support additional equipment. Plan dock areas and yard space for increased volume. Modular designs allow reconfiguration as operations evolve over time.

What ceiling height is optimal for modern warehouse operations?

Modern distribution warehouses typically feature clear heights of 32 to 40 feet, allowing for high-density racking storage. Higher ceilings maximize storage capacity on your land footprint but require appropriate material handling equipment. Consider your inventory characteristics, racking plans, and fire code requirements when determining optimal height for your operation.

How should I plan for technology in a new warehouse?

Install robust network infrastructure throughout the facility including wireless access points for mobile devices. Plan adequate power and data connections for workstations, printers, and automation equipment. Consider future technology like automated storage systems, conveyor integration, and robotics. Invest in infrastructure that supports technology adoption rather than limiting it.

What sustainability features should new warehouses include?

Consider LED lighting with motion sensors, high-efficiency HVAC systems, and solar panel readiness. Insulation and building envelope design affect energy costs significantly. Electric vehicle charging infrastructure supports fleet electrification. Water management features reduce environmental impact. Sustainable buildings often qualify for incentives and appeal to environmentally conscious clients.