Checklist to Set Up a New Warehouse

Setting up a new warehouse requires careful planning if you want to get the most out of your available space from day one. From layout design and racking configuration through to selecting the right materials handling equipment, every decision you make early on will affect how efficiently your operation runs for years to come. Below, Bendi Australia will share a practical checklist that covers the essentials.

Space, Layout and Vertical Storage

The foundation of any well-functioning warehouse starts with how the space is laid out. Aisle widths should match both your storage needs and the equipment you plan to use, and it’s worth considering narrow aisle solutions early rather than defaulting to wider aisles that eat into your storage capacity. Fully utilising vertical space is equally important, as safely stacking higher racks allows you to store more within the same footprint. Make sure your pathways can accommodate the specific equipment your operation requires, whether that’s articulated forklifts or side loaders. Your layout should also account for future growth and seasonal variations in stock levels.

Bendi Australia offers free site surveys and warehouse layout consulting to help you identify the most efficient configuration. Our articulated forklifts can operate in aisles as narrow as 1.8 metres, increasing storage capacity compared to a standard layout.

Pallet Storage and Product Flow

How you organise your pallet storage has a direct impact on picking speed and overall throughput. Fast-moving items should be positioned for easy access, while slower-moving stock can sit in less accessible locations. Planning efficient pallet turnover from the outset will minimise unnecessary handling and reduce operator travel time. It’s also worth considering how fragile or irregularly shaped loads will be stored, as these items may need dedicated zones to avoid damage.

Choosing the Right Equipment

Selecting the right forklift is one of the most important decisions you’ll make during setup. An articulated forklift like a Bendi handles both indoor racking work and outdoor trailer loading with a single machine, eliminating the need for multiple forklift types. If your operation involves unusual or heavy loads, consider whether a specialised machine is also needed.

Here are some key factors to consider:

• Whether your aisles require a narrow aisle solution or can accommodate conventional forklifts
• The maximum lift height you need to reach your highest racking bay
• Whether the forklift needs to operate both indoors and outdoors
• Total cost of ownership, including maintenance and energy costs
• The number of machines needed and where they’ll be positioned within the layout
• Operator training and ergonomic requirements for the chosen equipment

Safety and Future Planning

Your warehouse design should minimise the risk of product damage by accounting for how goods are handled at every stage. Regular safety checks on pallets, racking and equipment should be built into your standard operating procedures from the very beginning. Planning for future upgrades is equally important, as building flexibility into your layout now means you can later adapt to changes in demand or incorporate new technology without a complete overhaul.

Bendi Australia’s warehouse consulting team can help businesses plan for both immediate needs and long-term growth, with over 30 years of experience and nationwide service support.

Get Expert Warehouse Setup Advice from Bendi Australia

At Bendi Australia, we’re here to help businesses set up smarter warehouses that maximise storage capacity and improve productivity from day one. Call us on 1300 462 363 or request a free quote online today.