Coghlan, a leading third-party logistics (3PL) provider, has revolutionised its warehouse operations by implementing Dematic’s ColbyRACK high-density storage and mezzanine solution.

Designed and installed by Colby Storage Solutions distributor, Storage Ideas, the innovative setup has boosted storage capacity, optimised workflows, and cut operational costs, all without requiring a larger facility footprint. This transformation allows Coghlan to accommodate growing customer demands while maintaining cost efficiency in an increasingly expensive real-estate market.

Future-proofing warehouse operations

With a growing client base and rising inventory volumes, Coghlan sought a solution to maximise storage efficiency while controlling operational expenses. The company’s previous warehouse layout, a legacy configuration inherited from a prior occupant, had inefficiencies that limited storage capacity and increased handling times. To address these challenges, Coghlan partnered with Storage Ideas to design a high-density system featuring double-deep Dematic ColbyRACK storage and a raised storage mezzanine.

The new warehouse configuration features strategically positioned double-deep ColbyRACK racking, reducing the number of aisles and enhancing inbound pallet handling. Bulk storage was placed near dock areas to minimise travel distances for put-away and retrieval.

A two-level mezzanine accommodates Coghlan’s rapidly growing e-commerce business by providing dedicated storage for small, hand-picked SKUs. This structure, fitted with pick bays and premium 38mm Unilin flooring, improves operator efficiency by reducing travel distances and enhancing safety.

“The new building’s shape, along with double-deep racking and a raised storage area, gives us a structurally superior layout,” says Rolf Kater, CEO at Coghlan. “The greater visibility allows us to spot issues before they escalate, and the shorter travel distances mean we get more work done every day. We have more capacity and better flow than ever before.”

Overcoming challenges with local engineering expertise

During installation, an unexpected change in fire regulations required modifications to the mezzanine’s sprinkler clearance. Dematic’s local engineering team rapidly redesigned support beams, ensuring compliance without major project delays.

“This was a classic case of problem-solving on the fly,” says Nathan Burke from Storage Ideas. “In less than three weeks, Dematic turned around new parts while still supporting the original load requirements. If the racking had been imported, that process could have taken months.”

Immediate impact and long-term scalability

Coghlan’s new warehouse now accommodates 8,955 pallet positions, exceeding initial expectations by 10%. The improved pick-and-pack workflow has significantly reduced operator travel time, while double-deep racking has lowered real-estate costs per pallet by maximising vertical storage.

“We’ve significantly increased capacity and improved our pick efficiency without breaking the bank,” says Kater. “The best part is how scalable the design is. We’re already planning to expand the mezzanine to support ongoing growth, and that will help us stay ahead of rising demand.”

As Coghlan continues to evolve, the project showcases how strategic racking choices, methodical planning, and local manufacturing expertise can empower 3PL providers to adapt to high-volume demands efficiently.

“This is more than a warehouse upgrade – it’s a tool for us to grow our 3PL business,” concludes Kater. “New clients walk in and immediately see the efficiency and care that went into our layout. Working with Storage Ideas and Dematic has been an excellent experience, and it gives us a confident path forward as our operation expands.”