Building a New Warehouse? Here’s How to Streamline it for the Future

From automation to drones, new technology is disrupting the warehouse and cold storage industry. The demand for same-day delivery, and other concerns related to ecommerce, is forcing warehouse operators to transform their distribution and delivery processes. As more operations become digitally outfitted with WMS and other necessary tools, how inventory is stored, tracked, picked, and delivered will change, which requires owners to make the necessary changes at their existing facilities.

But what if you are building a facility from scratch? What things must you consider when working in the initial planning and site selection stages? Here are a few:

Sustainability in Modern Warehouse Design

Building a sustainable warehouse offers immediate and long-term operational benefits while reducing environmental impact. Energy-efficient lighting systems using LED technology with smart controls and motion sensors can reduce electricity consumption by up to 75% compared to traditional lighting. Combine this with optimized HVAC systems that use zone-based climate control to minimize energy waste in areas with different temperature requirements.

Solar panel integration on warehouse rooftops provides an excellent opportunity to generate renewable energy, given the large surface area typical of distribution facilities. Many operations achieve significant utility cost reductions while taking advantage of tax incentives and rebates. Additionally, installing EV charging stations for fleet vehicles positions your operation for the transition to electric delivery trucks and employee vehicles.

Design dedicated sustainable packaging stations that accommodate recyclable materials, right-sizing equipment, and waste reduction processes. These areas should include space for packaging material recycling and storage of eco-friendly alternatives.

Pursuing LEED certification demonstrates environmental commitment while potentially reducing operating costs through improved building performance. LEED-certified warehouses often experience lower utility costs, improved indoor air quality, and enhanced property values. Consider features like natural lighting optimization, water-efficient fixtures, and sustainable building materials during the design phase. These investments in green infrastructure typically pay for themselves through reduced operating expenses while supporting corporate sustainability goals and potentially attracting environmentally conscious customers and partners.

Planning Your Technology Infrastructure from the Ground Up

Establishing robust technology infrastructure during warehouse construction prevents costly retrofitting and ensures seamless operations from day one. Network backbone planning requires running fiber optic cables throughout the facility to support high-speed data transmission between various operational zones. Install conduits and cable trays that can accommodate future expansion and technology upgrades.

RF and WiFi coverage planning demands careful consideration of warehouse layout, racking height, and potential interference from metal structures. Design wireless networks with adequate access points to ensure consistent connectivity for mobile devices, barcode scanners, and tablets throughout the entire facility, including dock areas and upper storage levels.

Plan power and data drops strategically throughout the warehouse floor to support future automation equipment, conveyor systems, and mobile workstations. Include dedicated circuits for high-power equipment and ensure adequate electrical capacity for growth. Consider installing floor boxes or overhead power distribution systems in areas where automation might be deployed.

WMS server room requirements include proper HVAC, uninterruptible power supplies, and security measures if hosting on-premises. Alternatively, plan for reliable internet connectivity to support cloud-based warehouse management systems. Include redundant internet connections from different providers to ensure operational continuity.

Integrate building management systems with operational technology to monitor environmental conditions, energy usage, and security systems through centralized dashboards. This foundation enables data-driven decision making and supports advanced analytics as operations mature.

Location, Location, Location

Getting closer to customers to meet increasing demands is playing a role in location. The site you pick matters. In the past, companies tended to construct large warehouse operations in rural areas far from city centers. The reason was simple: The land out there is cheap and plentiful. With next-day and same-day shipping, it is becoming more of a priority to locate distribution centers in the heart of cities. Look at Amazon’s current push to have cities compete to have the company relocate to their respective urban center.

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Focus on Ecommerce

Traditional warehouse layouts accommodated bulk distribution for brick-and-mortar operations. Cases of goods were picked, packed, shipped, and delivered using multiple pallets and many trucks. That dynamic has changed with ecommerce. Now, with small volume ordering and delivery the focus, items have to be picked individually. That means the physical space of your warehouse needs to be designed to reflect, not just the different demands, but also to allow for the easy processing of returned items.

Accommodate the Robots

With automation emerging in the warehouse space, your new warehouse needs to be designed to allow for the infrastructure it requires: autonomous vehicle pathways, and vertical space to accommodate transportable shelving, conveyors, and other tools. Temperature control is also a factor. Optimize your space so that it puts the focus on your new automated technologies, even if you plan to incorporate them as you grow, because you don’t want to discover your new facility lacks the dimensions needed to eventually get your robotics up and running.

Invest in 3D modeling

The best way to plan for a new facility is 3D modeling that helps you identify potential bottlenecks involving the convergence of humans and robotics. Get your designer to figure out how to maximize vertical space and to keep dead space at a minimum. The modeling can also produce fly-through videos that can help in potential collision detection, and be used by other partners like vendors who can sync up plans with their demands in an effort to make the entire project as feasible as possible.

Are you designing a new facility? How have you readied it for WMS? Which components do you have and which ones do you need? Did you know your WMS can help you get and stay organized? Let us know in the comments below!

Frequently Asked Questions

What should I prioritize when designing a new warehouse layout?

Prioritize efficient product flow from receiving through shipping, minimizing travel distances for high-frequency movements. Design adequate staging areas for receiving, packing, and shipping operations. Plan storage areas based on product characteristics and velocity. Include space for value-added services if applicable. Allow room for future growth and layout modifications.

How do I determine the right size for a new warehouse?

Calculate storage requirements based on inventory levels, product dimensions, and turnover rates. Add space for operations including receiving, shipping, packing, and aisles. Factor in growth projections for at least five years. Include office space, break rooms, and support areas. Building somewhat larger than immediate needs provides flexibility as requirements change.

What dock door configuration works best for warehouse operations?

The number of dock doors depends on receiving and shipping volumes and the types of trucks you handle. Separate receiving and shipping docks improve workflow control. Consider dock levelers, shelters, and lighting for efficiency and safety. Include adequate yard space for truck maneuvering and trailer storage. Future expansion potential should influence initial door positioning.

How should I plan for automation in a new warehouse?

Design clear spans and ceiling heights that accommodate future automation equipment. Install robust power and data infrastructure throughout the facility. Consider floor flatness requirements for automated guided vehicles or conveyors. Plan IT room space for automation controls. Even if not implementing automation immediately, building ready for it costs less than retrofitting later.

What operational software should be implemented in a new warehouse?

A warehouse management system provides the foundation for efficient operations, inventory accuracy, and visibility. Integrate with your ERP or accounting system for seamless data flow. Consider yard management, labor management, and transportation management systems based on operational complexity. Implement software before or during startup rather than struggling with manual processes first.