Not every product offered by a manufacturer or distributor can be put in a regular, standard box or pallet for storage in a warehouse. Heavy, bulky items and irregular shapes need to be stored in ways that save on space and can be handled efficiently and safely. Items like rounds of ice cream or triangular boxes don’t fit nicely on storage racks because of their odd shape, size and weight. Putting these items individually on storage shelves can be difficult if shelves are made of wire where the items may tilt and not sit straight, making them unsafe for storage and handling. Distribution centers should be designed to store heavier items within the golden zone, the area closest to the picker’s waist, which doesn’t require them to bend or reach.
Dense, heavy products often must be handled manually because of their size and weight. In the warehouse, workers will manually pick these heavy items from pallets on the floor or on racks. To reach items in the back of the shelves, workers have to reach deep into the racks and pull items forward. This can harm the picker’s back, pulling the awkwardly shaped and heavy item. If workers are commonly fatigued or injured, productivity can suffer.