Warehouse Design Consultancy

Designing best-in-class warehouse operating solutions

Warehouse Solution Design

ASCALi’s Warehouse Consultants make sure that you design the right fulfilment solution to meet your current and future operating needs. From the smallest SME e-commerce operations right up to the most complex automated multi-channel fulfilment solutions, our team can help you size, design and create the business-case for your new distribution centre.

Warehouse layout design and evaluation

Delivering Great Warehouse Solutions that add service value and efficiency

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Whether new build, refurb or refresh, our team of expert solution designers are able to design and specify the right warehouse solution for your needs.

Our approach is very clear and open, and we work closely with you to ensure that the solution design fits your precise requirements for now and for the future.

Critical to success is our approach to learning about your needs, that focuses strongly about the things that make your business profitable, and that keep your customers coming back to you. We then align these factors to solutions that provide the best possible return on investment to ensure you develop lean, cost effective solutions that last.

Automated warehouse solution design and evaluation

Used the right way, automation can bring supreme efficiency

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Our team have implemented, worked in and designed automated solutions in a range of environments.

We know that not all automation needs to be hugely complex. Often the best uses of automation can result from the most simple but effective designs. We can help you to evaluate what would and would not be right for your operations and can help you access the right automation providers to supply what you need.

Our experts’ knowledge of the ever evolving robotics and automation landscape can help you to establish the most viable solution for you with the best return on investment.

Product layout design

Ultimate Optimisation of your solution making your operations efficient

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A great solution design delivers the best results when the finer points of its design are truly optimised.

Designing and balancing product location layouts safely and efficiently in your warehousing can help you achieve those few extra incremental points of efficiency improvement that can make all the difference to your bottom line.

Our team of highly experienced warehouse optimisation experts can help you plan out your detailed product layout to guarantee that every time you ask your staff to assemble a customer order, it takes the shortest amount of time possible.

We will align your layouts to match your best processes to keep efficiency high and congestion low. If we think your processes cold do with optimisation, our experts will advise on that too.

Case study

Designing a new warehouse for a Global Leisure Products Brand

This case study demonstrates that when you are in a tight situation there is always a better way.

The client ws in a precarious position with a soured relationship with a third-party logistics operator and needed fast results, and change delivered quickly.

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Frequently Asked Questions

Are you experts in warehouse solution design, implementation and optimisation?
Our team have been delivering warehouse consultancy solutions since 2002. We have built an enviable track record of delivering results for our clients to help them reduce cost, improve service and increase overall business efficiency in their warehousing operations.
Do you manage warehouse transition?
Yes, we can help you change an existing solution or move from one operation to another. Whilst every project is different, we follow a tried and trusted methodology to ensure that we engage the right people in the process and deliver your change in a cost-effective and timely manner. We specialise in delivering operational solution expertise to the process to ensure that not only do we manage the transition, but we add value as you move through the change. This expertise provides our clients the confidence they need to deliver change successfully.
Can you help us improve warehouse capacity?
Yes, we can identify ways to get the best possible operating capacity in terms of storage and throughput for your warehouse operations. We can help you identify manual and automated techniques and solution layouts to help you access the most efficient storage solution for your organisation.
Do you design food warehouses?
Yes, our team has both operated and designed all manner of different food warehouse solutions from FMCG, ambient product, frozen warehouses, and chilled goods warehouses. We are conversant in flowthrough and line-pick operations as much as case and unit pick from stock solutions. Our team can design Solutions for any type of food distribution business. See our Case Studies.
Do you design e-commerce warehouses?
Yes, we design manual, partially automated and automated e-commerce warehouse solutions for our clients. We also work with clients on multi and Omni channel solution design for businesses, serving retail, wholesale and B-2-C customer bases. We have designed solutions across a range of sectors and can help all sizes of business achieve the optimal e-commerce solution design.
Do you supply racking?
No, we are not a racking vendor. We work with all the main racking vendors to help ensure where we design solutions, that our clients get the best possible value for the right type of equipment.
Do you only design manual warehouses?
No, we also design automated solutions for our clients. We work with all the main solution integrators to create designs that give you the best mix of operating characteristics to meet your requirements. We do not only provide designs based upon one solution vendor’s options as this limits your ability to get the right solution.
Are you experts in warehouse management systems?
Yes, we can help you Scope, select and implement the right warehouse management system technology to support your business needs. This can include full WMS solutions as well as partial warehouse control systems, solutions and picking media.
Can you help us reduce warehouse cost?
Yes, no matter what size of operation you have, we are confident that we will be able to help you identify ways to reduce your operating cost or increase your service levels. We have done this in the smallest of operations with Challenger growing companies as well as for some of the biggest names in the world of retail and manufacturing. We can do this across multiple sites and countries where required or in a single operating facility.
Can you help us implement a new warehouse solution?
Yes, we help our clients from the earliest design stages, right the way through to full implementation of their warehouse solutions. We can do this for solutions we have designed or will do it for you if you have your own solution design in hand. We are happy to work with you to provide the right level of support to help you ensure your new DC implementation is delivered on time to budget.
Can you help us develop environmentally sustainable solutions?
Yes, we can help you design new warehousing and enhance existing warehousing through the application of the best mix of energy performance and sustainable environmental solutions. We can help you evaluate means of reducing your energy costs, as well as delivering zero carbon electricity and energy generating solutions.
Do you design automated warehouses?
Yes, we design both manual and automated warehouse solutions. Our team is fully conversant with all the latest technologies being deployed across warehouse operations that can add value to a range of different operating sectors. Our team has designed and implemented automated warehouse solutions in manufacturing retail and e-commerce environments for a range of clients.
Do you support warehouse outsourcing?
Yes, with experience from both sides of the outsourcing line, 3PL and contracting partner, we can help you identify the best solution vendors to help you fulfil your service aspiration. We can then work with you right the way through the process to ensure that your third-party logistics provider delivers upon their promises to you to ensure that your costs are minimised and your service is maximised.
Do you have any warehouse jobs?
No, we do not operate our own warehouses and do not recruit warehouse or transport staff directly.
What size of warehouse do you design?
We work with a very broad mix of sizes and shapes of business. We have designed warehouses from 2,000ft² up to 1,000,000ft² for our clients. Whether you are a challenger business growing at the outset of its development, or a well-established scale business with a large distribution requirement, we can design you a solution that fulfils your needs in the most cost-effective way.
Are we too small for you to help us reduce our cost?
Almost certainly not. We will conduct reviews for small clients that are delivered quickly and with output that will help you achieve benefit. No matter how small your operation, we can tailor a work package to give you what you need to drive benefit in as little as 2 to 3 days, depending on the scale of your operations.
Do you design warehouses?
Yes, we have designed hundreds of warehouse operations across the UK and Europe. Our specialist team of warehouse designers are expert at understanding your businesses needs and ensuring that your warehouse is designed cost effectively and efficiently to meet your requirements.
Can you optimise warehouse operations?
Yes, we can work with you to identify a range of options available to help you optimise your solution. This can cover a range of activities such as operational, layout, reviews, process, reviews, organisational structure, review, and cost and key performance indicator review. We tailor our approach to meet your needs and help you get the best from the process.
Do you operate warehouses?
No, we do not as a business typically operate our own warehousing. However, where you may have specific operational requirements, we can help you draft in managers and teams of experts to help you manage your business as usual or project implementations. We can do this for as long or as little, as you need to ensure your operations get to and remain stable and effective.
What information do you need to design a warehouse?
We will work with you to build the best mix of operational data and business understanding to ensure we capture your needs fully in our warehouse design process. We will work with you to build the best possible picture of your business and will help you bridge gaps in data and information to ensure that the design process is robust and gives you the solution you need.
Do you design big warehouses?
Yes, we have designed warehouses up to 1,000,000ft² in footprint. Our team are happy to work with clients, big and small in developing their warehouse solution designs. We are not deterred from looking at different scales of operation, and having designed and operated many big warehouse operations. We are extremely experienced at understanding the challenges and requirements for such projects.
Are you warehouse labour agency?
No, we do not provide agency labour or recruitment services.

Our Team Has Worked With Great Brands ...

Currys Logo
Hovis Logo
Texaco
Carlsberg Logo
Bidfood Logo
Natures Menu Logo
ASDA Logo
Efes Logo
Mitchells & Butlers Logo
L'oreal Logo
WDFG Logo
NHS Logo
Londis
Cott
Argos
B&Q
BAKO
Marks and Spencer
KPSnacks
Yorkshire Water
WeightWatchers
Panasonic
Waitrose
Nuffield Health
Coop
Bernard Matthews
Cadbury
Noble Foods
B&M Bargains
Magnet