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Order accuracy and picking speed are make-or-break metrics for any high-volume distribution operation. For one of Logistic Packaging’s clients, a major distribution warehouse in Romania handling thousands of SKUs daily, a disorganised racking system was quietly costing time, money, and customer trust. The solution came in the form of our modular storage bins for warehouse racks, and the results speak for themselves.
The Client’s Problem: Chaos on the Racks and Errors at the Picking Stage
The warehouse in question operates across a large multi-aisle racking facility, managing a mixed inventory of small-to-medium components, spare parts, and consumer goods. As order volumes grew, the limitations of their existing storage approach became impossible to ignore.
Items of different sizes were grouped together on open shelves without defined compartments. Pickers had to visually scan entire rack bays to locate individual SKUs, wasting valuable seconds on every single order line. In a facility processing hundreds of orders per shift, those seconds added up to hours of lost productivity each day.
Beyond speed, accuracy was suffering. Without clear physical separation between product categories, mis-picks were a regular occurrence: wrong items, wrong quantities, wrong locations. Each error triggered a return, a repack, and a frustrated customer. The warehouse manager estimated that pick errors were affecting roughly 8% of outbound orders, a figure that was generating significant downstream costs and straining relationships with key clients.
The racking structure itself was underutilised. Large sections of shelving held loosely arranged products that could not be organised into the available vertical space, leaving usable capacity wasted.
The Logistic Packaging Team Evaluates the Situation
After an initial consultation, a Logistic Packaging specialist visited the facility to conduct an on-site assessment. Several critical issues were immediately apparent:
- Rack bays had no consistent slotting logic: products were placed wherever space existed rather than in defined locations
- The absence of storage bins for racking systems meant there was no physical barrier between different SKUs on shared shelves
- Small, loose items were frequently misplaced or fell behind larger products, making them invisible to pickers
- Label placement was inconsistent, making barcode scanning unreliable and slow
- The warehouse could not scale its current layout to accommodate growing SKU counts without a full racking overhaul
The root cause was clear: the facility needed a modular, standardised containment system that could integrate with their existing racking infrastructure without requiring any structural changes.
Our Solution: Modular Storage Bins for Warehousing
After completing the evaluation, our team recommended Logistic Packaging’s range of modular storage bins, a purpose-built solution for storage bins for warehousing environments that demand flexibility, clarity, and efficiency.
The modular bins are available in six sizes, ranging from compact 160×100×75 mm units up to larger 500×315×200 mm bins, allowing the warehouse to match bin size precisely to product dimensions.
Their optimised footprints are designed to work in any combination on standard shelving and racking systems, making full use of both horizontal and vertical rack space. Each bin is manufactured from high-quality plastic in blue or red, enabling a simple but effective colour-coding system to distinguish product categories or picking zones at a glance.
The open-front design gives pickers immediate visual access to bin contents without removing or repositioning anything. Labels and barcodes can be applied cleanly to the front face of each bin, making scanning fast and reliable. For a warehouse processing high order volumes across multiple shifts, this seemingly small detail has a measurable impact on daily throughput.
The Client Implements the Recommendation
The warehouse rolled out the modular storage bins across its primary picking aisles, using the smaller LP-MB-1610-75 and LP-MB-2315-12 bins for high-velocity small parts and the mid-range LP-MB-3521-15 and LP-MB-5031-20 bins for bulkier product categories. Colour coding was introduced immediately, with blue bins assigned to fast-moving SKUs and red bins reserved for items requiring special handling.
Within the first three weeks of deployment, warehouse staff reported noticeably faster pick cycles. The defined slot for every SKU eliminated the visual searching that had previously slowed every order line.
Results That Made the Difference
The deployment of modular storage bins for warehouse racks delivered measurable gains across all key performance indicators:
- 45% reduction in average pick time per order line, driven by instant product visibility and consistent slotting
- Pick error rate dropped from 8% to under 1%, thanks to physical separation of SKUs and improved label placement
- 30% increase in effective rack capacity by fully utilising vertical space with sized bin combinations
- Significant reduction in mis-ship costs and customer complaints in the first quarter post-implementation
- Faster onboarding of new pickers: the colour-coded, logically slotted system cut training time considerably
Today, the warehouse operates with a level of organisation and picking discipline that has become a genuine competitive advantage, supporting continued growth without the need for costly infrastructure investment.
Logistic Packaging is more than a supplier of returnable packaging solutions. We are a long-term partner that helps your business identify the best tools for your logistics operations, reducing costs and improving efficiency at every step. Send us an email to discuss your storage project with our specialists!
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