Warehouse Racking Systems

Lucy & Yak, a sustainable clothing brand known for its inclusive and gender-neutral designs, faced challenges scaling its warehouse operations. After moving into a 39,000 sq ft facility in Barnsley, South Yorkshire, inefficient floor-stacked storage limited the use of available space and led to high picking error rates. The existing system could only utilise 9,000 of the theoretical 12,800 carton capacity, wasting nearly 4,000 carton spaces.

Challenge: Underutilised Warehouse Space

The inefficient storage layout hindered operations. Stacking cartons with single SKUs led to frequent disruptions, limited accessibility, and wasted space. Lucy & Yak needed a more efficient system to maximise storage, improve picking accuracy, and support operational growth.

Solution: Static Longspan Shelving by Link51

Following a competitive tender, Lucy & Yak partnered with Link51, a Whittan brand, to install static Longspan shelving. The project was carefully planned to minimise disruptions, with installation taking place post-peak sales and executed row-by-row. This ensured the warehouse remained operational throughout the upgrade.

Impact: Improved Capacity and Efficiency

The new system added 366 bays of shelving, increasing storage capacity to 12,800 cartons. The single carton-per-location system reduced picking errors and optimised workflow, enabling staff to handle up to 25,000 units weekly without increasing the workforce. The warehouse now operates with 92% space utilisation, laying the foundation for future growth, including a planned mezzanine installation.

Why Choose Whittan?

Whittan’s expertise in warehouse racking systems and tailored storage solutions for retail and e-commerce ensured Lucy & Yak achieved maximum efficiency, aligned with their ethos of sustainability and growth.