The Brief

QTS was tasked with supporting a longstanding multinational pallet racking manufacturer in delivering a large-scale storage solution for an e-commerce fulfilment warehouse.

The facility handles thousands of inbound and outbound packages daily and required a robust, efficient shelving system. A key challenge was the compressed delivery and installation programme, with 43,639 shelving levels (1200mm x 3600mm) required within a strict timeframe. Phased delivery requirements added further complexity, demanding careful coordination of manufacturing, logistics and on-site installation to ensure deadlines were met without compromising quality or operational efficiency. The solution also required a balanced ratio of wire mesh decks and dividing hooks to support the warehouse’s picking operations.

Key Statistics

131,665
Wire Mesh Decks

331,770
Custom Dividers

94
Containers

< £1.2m
Project Value

The Solution

Standard imported wire mesh decks were installed across all shelving levels, providing a sturdy, reliable and cost-effective solution for picking operations. The powder coated finish creates a smooth, sharp-free surface that helps protect both operatives and goods.

To manage the project’s scale, QTS coordinated the shipment of 94 sea containers, with up to 21 containers delivered in a single week at peak activity. A detailed tracking system monitored shipments and logistics, ensuring accurate coordination and clear communication throughout the project.

Innovative Design Spotlight

QTS delivered a bespoke storage solution designed to support the project’s scale and complexity. Custom interlocking divider hooks were developed to create a flexible shelving system adaptable to the operational requirements of the e-commerce warehouse.

The Results

The project was a resounding success, a testament to QTS’s capabilities. We successfully met the tight deadlines, delivering the first half of the shelving levels by the start of July and the remaining balance by the end of July, well ahead of the overall project completion date at the end of September. The customer appreciated the bespoke divider hook solution, which perfectly suited their customer’s needs, and the transparent communication maintained throughout the process via the shared spreadsheet and project updates.

Craig De-Lara, Managing Director of QTS had this to say on the project:

“I am extremely proud of what this project represents for our business. At the time, it was the largest single order value we had secured, marking a significant milestone in our growth.

The brief presented both technical and operational challenges, including a complex mesh deck and divider solution, tight spatial constraints, and a demanding programme. Our team worked closely with the customer to refine the design, optimise the layout, and carefully coordinate manufacturing and logistics to ensure the project was delivered on time while maintaining our standards of quality and safety.

The successful completion of this project demonstrates QTS’s ability to deliver large, technically demanding storage solutions and reinforces our position as a trusted partner for complex engineered projects.”

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