F.Ball and Co
F. Ball and Co. Ltd., a leading manufacturer of subfloor preparation products with over 60% of the UK subfloor preparation market, has completed a full warehouse racking reconfiguration at its Churnetside Business Park site in Staffordshire, in partnership with Logisnext UK. Logisnext UK has been the company's materials handling supplier for more than 40 years.
UK's leading manufacturer of subfloor preparation products boosts storage capacity by 9%
What was the challenge?
F. Ball and Co. had operated a double deep racking configuration for many years. As the company's SKU range grew substantially, the double deep layout became increasingly inefficient for day-to-day operations.
Why this product(s)?
Five new RB20N3 reach trucks with a lift height of 6.75 metres were matched precisely to the new racking height to maximise vertical storage.
What was the outcome?
Operatives can now access any pallet immediately, removing the time-consuming workaround that double deep storage had required.
Innovative solutions for a live operation
F. Ball & and Co. has been a Logisnext customer for over 40 years. The strength of that long-term relationship was a key factor in the decision, alongside the ability to deliver both the racking and materials handling solution as a single, integrated solution.
While competing proposals from major suppliers were broadly comparable on price, it was the consultative approach, flexibility, and track record of service that ultimately won the project. The new single deep racking solution also standardised operations across both warehouses on site — one of which had previously run standard reach trucks, while the other used double deep trucks.
The project was delivered in three carefully sequenced phases: lighting installation, racking erection, and simultaneous sprinkler installation by Richmond; all while the warehouse remained operational.
The five new RB20N3 reach trucks with a lift height of 6.75 metres were matched precisely to the new racking height to maximise vertical storage. The project came in under budget and was completed on schedule.
The phased installation was extremely successful; the racking team worked really well with us to ensure that deadlines were met on time. On occasion, some of the new racks were made available to us earlier than planned, which was very useful. There was racking being dismantled and erected on site at the same time as we were running the warehouse and all activities were fully compliant with health and safety requirements.
Proven Results
The reconfigured warehouse has delivered measurable improvements across storage, safety, and daily operational efficiency. Pallet count on site increased by approximately 230, a gain of around 9%, and was enabled by the greater racking height. Operatives can now access any pallet immediately, removing the time-consuming workaround that double deep storage had required.
The fleet is supported by a full maintenance contract with a dedicated field service engineer, and the account continues to be managed through regular quarterly reviews, a model that has served the partnership well for four decades.
Overall the new layout has delivered us more storage capacity, and a more efficient environment, it came in under budget with no impact on the delivery of orders to our customers.
Why this soultion
F. Ball and Co. has been a Logisnext customer for over 40 years. The strength of that long-term relationship was a key factor in the decision, alongside the ability to deliver both the racking and materials handling solution as a single, integrated solution.
While competing proposals from major suppliers were broadly comparable on price, it was the consultative approach, flexibility, and track record of service that ultimately won the project.
This was a very rewarding and enjoyable project to be a part of. By working closely together and each party being flexible when required, it was possible to complete the project ahead of schedule
Award-winning warehouse range
Engineered to deliver maximum performance, while keeping energy consumption to a minimum.
