How to optimise warehouse space for maximum efficiency
As we navigate 2025, the UK’s retail sector faces a complex economic landscape. The National Institute of Economic and Social Research (NIESR) forecasts modest GDP growth of 1.2% this year, with potential downturns if global trade tensions escalate. Despite these challenges, the Interactive Media in Retail Group (IMRG) anticipates a 1% year-on-year increase in total market revenue, buoyed by consecutive growth in online sales since late 2024.
Compounding these dynamics is a persistently tight labour market. NIESR notes that, although the unemployment rate has risen to 4.4% as of May 2024, the labour market remains tight by historical standards, as evidenced by a vacancies-to-unemployment ratio that, despite falling, remains higher than its historical average.
In this environment, optimising warehouse efficiency becomes crucial for retailers aiming to maintain profitability and meet evolving consumer demands. Enhanced warehouse operations can lead to faster delivery times, reduced costs and improved customer satisfaction, providing a competitive edge in a fluctuating market.
In this blog we will explore the equipment available and strategies to streamline warehouse processes, helping retailers thrive amid economic uncertainties.
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Warehouse organisation solutions
A well run, efficient warehouse starts with goods put away and picking. By ensuring that the stock is well ordered and easy to find, you can support a quick and seamless picking process to deliver your ordered products to the packing area.
Pick bins
Pick bins are a simple yet effective way to improve order-picking efficiency. By organising small to medium-sized items in dedicated, well labelled bins, warehouse operatives can quickly access stock, reducing picking times and errors. These bins help streamline order fulfilment and make the most of vertical storage space.
Racking space for larger items should also follow the same principle of clear location labelling.
Warehouse tidy accessories
A well-organised warehouse is a productive warehouse. Using rack sacks, floor marking tape and other tidy accessories ensures a clean and safe working environment.
Rack sacks help with efficient waste segregation, removing potential trip hazards and preventing clutter.
Floor marking tape clearly defines pathways and storage zones, enhancing workflow efficiency.
Products to enhance packing efficiency
The easier your packaging is to apply, the quicker your operatives can get your orders delivered to goods in. There are several products which are able to support your operatives, ensuring they can work quickly and efficiently.
Packing benches
Having dedicated packing benches allows workers to efficiently pack orders in a structured workspace. Customisable pack benches can include storage for packing automation – like void fill and tape dispensers, packing materials and paperwork.
By providing everything the packing operator needs to hand, you are reducing downtime and improving packing speed.
Anti-fatigue mats
For operatives who stand for long hours, anti-fatigue mats can significantly improve comfort and productivity. These mats reduce strain on the legs and lower back, leading to reduced risk of injury.
Mobile power workstation
One of the most exciting additions to warehouse efficiency is the Mobile Power Workstation. This innovative workstation allows operatives to take their workspace with them, wherever they go. With two interchangeable power packs which last a total of 16 hours, it’s enough for two shifts to pick, weigh, print, pack and put away goods whilst on the move.
Increasing flexibility by reducing the need for workers to return to a static workstation, it enhances productivity and efficiency in dynamic warehouse environments.
Automation for streamlined operations
Reducing the number of manual touches to a pack can also speed up the application of packaging. Here is just a selection of products which can help to increase productivity in the packing area.
In-box protection automation
Automated in-box protection solutions help to reduce packing time while ensuring that goods are securely cushioned for transit. These systems eliminate manual void fill processes, increasing efficiency and reducing material waste.
Available systems include paper void fill applicators like Ranpak FillPak® and Geami HV®systems, as well as airbag systems like Pregis Pro Pak’R® or Sealed Air Fill-Air Rocket®.
Box sealing automation
Upgrading to water-activated tape dispensers provides a secure, tamper-evident seal for packages. These dispensers reduce tape waste, speed up sealing times and enhance package security.
The entry level BP222 is suitable for businesses shipping low volumes of parcels, dispensing gummed paper tape at the push of a button. Whilst the BP555 is suitable for medium to large volume shipments, as it can be programmed to dispense pre-set lengths to suit a variety of shipment sizes.
Conveyor systems
Conveyor systems help move packages quickly and efficiently through the warehouse, reducing manual handling and the risk of workplace injuries. For entry level, conveyors with rollers can move goods with a gentle push from one station to another, whilst for larger operations a belted conveyor automatically moves goods through the various stages of your dispatch operation.
Implementing conveyor solutions speeds up packing and dispatch operations, improving overall workflow.
Stretch and strapping machines
For operations which are shipping or distributing goods by the pallet, stretch and strapping machines automate the pallet wrapping and securing processes, ensuring that shipments are stable and secure. These machines save time, reduce material waste and enhance load containment, preventing damage during transit.
Automated systems mean that whilst one pallet is being wrapped, operators have time to move pallets on to the next stage of the dispatch process.
Optimising warehouse space is not just about adding more storage; it’s about creating a smarter, more efficient workflow. Whether through smart storage solutions, ergonomic enhancements, automation or mobile workstations, investing in the right equipment can lead to significant time and cost savings.
Support optimising your warehouse space
At Macfarlane Packaging, we’re committed to helping you make the most of your warehouse space. Contact us today to find out how our solutions can enhance your warehouse efficiency and productivity.