Very Narrow Aisle Warehousing Explained: Maximise Space and Efficiency

Warehouse space is one of the highest ongoing costs for any Australian business that stores and moves physical goods. Very narrow aisle warehousing is a storage strategy that reduces the width of aisles between racking bays to increase the number of pallet positions within the same footprint. In a typical very narrow aisle setup, aisles range from 1.8 to 2.5 metres wide, which is a significant reduction compared to the 3.5 metres or more required for conventional forklift operations. In this blog post, Bendi Australia will run through how this approach works, how it compares to conventional warehousing and what equipment you’ll need to make it happen.

Narrow Aisle vs. Conventional Warehousing

Understanding the differences between conventional, narrow aisle and very narrow aisle setups is the first step in deciding which approach suits your operation. In a conventional warehouse, aisles are typically 3.5 metres or wider to accommodate standard counterbalance forklifts. Narrow aisle configurations bring that down to around 2.5 to 3.5 metres using reach trucks, while very narrow aisle setups reduce widths further to between 1.8 and 2.5 metres using turret trucks or articulated forklifts.

The trade-off with narrower aisles is that the initial investment tends to be higher, as you’ll need more racking and the equipment designed for tighter spaces can carry a higher price tag. However, the long-term savings are where the real value sits. Increasing your storage density means lower per-pallet storage costs, and the gains are often significant enough to delay or eliminate the need for a building expansion. With Bendi articulated forklifts, the cost equation is also more favourable than turret trucks because no guidance systems or specially prepared floors are required.

Understanding the Equipment Options

The equipment you choose will determine how narrow your aisles can go, so it’s worth understanding the key differences between the main forklift types used in warehousing.

• Counterbalance forklifts require the widest aisles at 3.5 metres or more. They work well indoors and outdoors but limit how much racking you can fit into a given space.
• Reach trucks are designed for aisles of around 2.5 to 3.5 metres and can extend their forks to place pallets at height. They perform well indoors but are not suited to outdoor use.
• Turret trucks operate in very narrow aisles and rotate their forks to place pallets on either side. However, they require guide rails or wire guidance and specially levelled floors.
• Articulated forklifts use a pivoting mast that rotates up to 220 degrees, allowing them to work in aisles as narrow as 1.8 metres without guidance systems or super flat floors. They also operate both indoors and outdoors.

Choosing the Right Solution for Your Operation

There’s no one-size-fits-all answer when it comes to aisle width and equipment selection. The size and layout of your warehouse will determine how much room you have to work with, while your throughput requirements will influence how quickly goods need to move in and out of racking. Budget is naturally a factor as well, and it’s worth looking beyond the upfront cost to consider total cost of ownership over the life of the equipment. Whether your operation involves outdoor trailer loading is another important consideration, as this will narrow down which equipment types are viable. Bendi Australia offers free site surveys and warehouse layout consulting to help you identify the most efficient configuration.

Speak to Bendi Australia About Very Narrow Aisle Solutions

At Bendi Australia, we’ve been helping Australian businesses maximise their warehouse space for over 30 years. Whether you’re setting up a new facility or optimising an existing one, our team can provide a free consultation to show you what’s possible. Call us on 1300 462 363 or request a quote online to get started.