Distribution Centre – Book Aid International

Storage Aspects have recently completed the full design and construction of a modern new distribution centre for Book Aid International. By working closely alongside the Book Aid team throughout every stage of the project, we have delivered a major upgrade to their facilities. This improvement will significantly enhance their ability to support their charitable mission, ensuring that books can reach communities and individuals around the world who need them most, promoting education and opportunity.

Beginning with an empty shell, we collaborated closely with the client to design and implement their new distribution centre. The project sought to maximise overall storage capacity while also streamlining and optimising the order picking, packing, and shipping processes. Every aspect of the layout and workflow was carefully considered to enhance efficiency and performance.

The new distribution centre delivered:-

• 180 pallet locations
• Over 12,500 carton locations
• Over 3 kilometres of pick shelving (that’s almost the length of 30 football pitches!)
• Goods in processing area
• Outbound packing and shipping work area
• All required safety and environmental systems for warehouse operations

• The new manual handling equipment includes a very narrow aisle (VNA) pallet truck, a man-up order picker, a counterbalance forklift truck, and powered pallet trucks. All designed to improve efficiency, safety, and productivity in warehouse operations.

• Charging station for manual handling equipment

• Line markings throughout the new warehouse, plus all safety signage

• Office uprights for the new staff members, including spacious desking areas, a fully equipped private meeting room, comfortable mess facilities. Plus welcoming break out areas designed for relaxation and collaboration.

• External storage container

Expansion of activities with the new Distribution Centre

• The expansion provided essential additional space, significantly enhancing the charity’s capacity to operate effectively, ensuring that everyone, regardless of their circumstances, has equitable access to books and educational resources.

Planning and Compliance

• Careful and strategic planning is required to maximise available storage capacity while also ensuring that workflow throughout the facility remains smooth and efficient. This includes optimising operational processes such as the handling of goods inwards, accurate receipting, timely order picking, careful packing, and onward shipment management.
• Ensuring full compliance with all relevant health and safety requirements, including strict adherence to CDM 2015 regulations for construction projects and site operations.

Surveys and Risk Assesments

• Building surveys and risk assessments
• Ground slab investigation surveys, comprehensive site assessments, and detailed structural engineer calculations for accurate analysis.
• Overall space planning
• Construction risk assessment

• Operational risk assessments covering MHE, manual handling, general workplace evaluation, as well as monitoring for legionella and asbestos hazards.
• Comprehensive project management of the entire build process, from initial conception through to final handover. Delivering a complete turnkey solution that is consistently achieved on time and within budget constraints.
• Collaborated extensively with the manual handling equipment supplier, coordinating detailed specifications and testing to ensure the equipment functioned seamlessly and safely with all pallet and carton racking installations on site.

• Provided comprehensive aisle grinding services to ensure smooth, level flooring, enabling the safe and efficient operation of high-level VNA trucks and order pickers within the warehouse racking system.
• Successfully co-ordinated and managed the complete installation process of the advanced electronic wire guide system for multiple trucks efficiently.

• We designed, supplied, and installed all labelling for pallet, carton, and pick shelving locations, collaborating closely with Book Aid to ensure correct location and barcode formats. Ultimately producing and implementing over 17,500 individual labels across the facility.
• All works are carefully installed by our highly experienced, fully qualified, and dedicated professional team members.

Summary

Storage Aspects designed and constructed a new distribution centre for Book Aid International, enhancing capacity to support their charitable mission. The project included maximising storage capacity, optimising order processing, and ensuring compliance with health and safety regulations. The new facility features over 180 pallet locations, 12,500 carton locations, and advanced manual handling equipment.

Gallery of more photos from the Distribution Centre – build and completion

Key Points

• Project Scope: Design/construction of a new distribution centre for Book Aid International, including storage, order processing, and office space.
• Storage Capacity: 180 pallet locations, over 12,500 carton locations, and over 3 kilometres of pick shelving.
• Operational Enhancements: Manual handling equipment. (VNA pallet truck, man-up order picker, counterbalance forklift truck, powered pallet trucks). Goods in processing area, outbound packing and shipping work area, and safety and environmental systems.
• Project Management: Provided comprehensive project management from conception to handover, delivering a turnkey solution on time and within budget.
• Safety and Compliance: Ensured full compliance with health and safety regulations, including CDM 2015. Conducted risk assessments for construction, operational, and environmental hazards.
• Warehouse Optimisation: Optimised operational processes, including goods handling, order picking, and packing. Provided aisle grinding and labelling solutions for efficient warehouse operations.
• Project Scope: Storage Aspects designed and built a new distribution centre for Book Aid International.
• Project Features: The new facility includes over 180 pallet locations, 12,500 carton locations, and advanced manual handling equipment.
• Project Benefits: The new distribution centre enhances Book Aid International’s capacity to support their charitable mission. This is by maximising storage capacity, optimising order processing, and ensuring compliance with health and safety regulations.

Unit 5 Timelapse

Unit 6 Timelapse

About Book Aid International