Project record
Reynolds systemsEagleville, PA
Streamlight
Production Floor Storage
70,000 SF Warehouse size
Verified projectView case
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Pallet racking, VLMs, and mezzanines optimize every cubic foot of your existing facility—with 12-month typical payback. No building expansion required.
200+ Warehouse Projects Completed
Streamlight, Mack Trucks, Air Products trust Reynolds
Warehouse Storage Optimization
Racking • VLMs • Mezzanines • WMS Integration
Reynolds uses measured layouts and confirmed operating data to evaluate warehouse capacity and workflow options.
Costs and schedules are confirmed from the same facility inputs
Vertical storage systems convert unused overhead cube into accessible capacity—without expanding the building footprint.
Reynolds confirms the facility, labor, configuration, and cost inputs before presenting savings or payback figures.
Built from measured and confirmed project inputs
Every solution comes with ROI projections. No surprises—just measurable results.
Vertical lift modules and pick modules for high-velocity fulfillment. Light-directed picking — 99.9% order accuracy.
Organized receiving areas with proper staging lanes and immediate put-away — 40% faster put-away time.
High-density shelving and VLMs maximize storage density. Pallet racking configurations optimized for your product mix — 85% more capacity.
Long-term partnerships—not one-time transactions
Published Reynolds projects connected directly to the underlying case-study record.
Production Floor Storage
Reynolds designed a new layout, replacing old shelving with a high-density movable shelving system — small-part shelving, wide-span shelving, and pegboard for odd-shaped parts like windshield wipers — plus stainless-steel countertops on shelf units for parts pass-through between the parts department and service techs, all painted in Fred Beans Blue.
From capacity assessment to an installed, operational system—built around your fulfillment schedule.
Reynolds audits your current storage utilization, picking workflows, and seasonal volume patterns.
VLMs, high-density shelving, and pick-to-light systems are configured around your fulfillment volume and SKU mix.
Systems are installed to the confirmed project schedule and site safety plan.
Staff are trained on the configured systems, with support routed through the Reynolds service team.
We've completed 200+ warehouse and distribution storage projects across Pennsylvania and the Mid-Atlantic. Get a free assessment of your specific space or throughput challenge — no pressure, no obligation.
Request ROI AnalysisFree • No obligation • Same-Day response
Hanel VLMs include inventory management software that integrates with major WMS platforms including SAP, Oracle WMS, Manhattan Associates, Blue Yonder, and others. Integration handles: pick list import, inventory updates, transaction logging, cycle count support, and reorder alerts. We configure the integration during installation.
Yes. Our steel mezzanines are engineered for specific load requirements—from standard 125 PSF for pick modules up to 500+ PSF for fully loaded pallet racking. We analyze your racking layout, product weight, and forklift traffic, then design the structure accordingly with stamped engineering drawings.
Most warehouse projects achieve payback in 12-18 months. ROI comes from: labor savings (60% faster picking), space savings (avoid relocation or expansion), accuracy improvements (99.9% eliminates re-ships), and throughput gains (handle more volume with same staff). We provide ROI projections with every proposal.
Project timing depends on site conditions, system type, engineering, product availability, permitting, and installation scope. Reynolds confirms a schedule after reviewing the site and requirements.
No. We design installation sequences to keep your operations running. Pallet racking goes in section by section. VLMs install in designated areas while existing operations continue. Mezzanines are assembled without disrupting floor-level activity. Most clients maintain 90%+ throughput during installation.
We've completed 200+ warehouse and distribution storage projects across Pennsylvania and the Mid-Atlantic. Get a free assessment of your specific space or throughput challenge — no pressure, no obligation.
Request ROI AnalysisFree • No obligation • Same-Day response
ROI and storage optimization resources for high-volume distribution centers.
A step-by-step method for calculating the return on a storage mezzanine: the cost-avoidance formula, a worked Lehigh Valley payback example, cost and comparison tables, hidden costs, tax treatment, the code and OSHA requirements that shape the budget, and when a mezzanine is not the right answer.
A definitive guide to warehouse storage optimization for operations leaders: cube versus floor utilization, the real 85 percent target, ABC slotting and the golden zone, honeycombing, vertical and aisle strategy, a worked dollar example, a step-by-step method, comparison tables, and when not to optimize for density.
From pallet racking to automated pick systems, Reynolds measures the facility and models capacity, cost, and workflow options from documented assumptions.
Tell us about your warehouse challenges. We'll analyze your specific situation and provide ROI projections—not generic estimates.
A specialist reviews your needs—no auto-responders
We pull case studies from similar projects in your industry
Optional on-site measurement at your convenience
Detailed proposal with transparent pricing—no hidden fees
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Pallet flow, vertical storage, and capacity-expansion guides for distribution operations.
