Industry: 3PL & Logistics
Project Type: Full Warehouse Fitout
Location: Airport Oaks, Auckland, New Zealand
Completion Date: January 2024
Who Are MAINSTREAM
Client Overview
Mainstream New Zealand is an innovative freight company specialising in domestic and international shipping, transport and logistics. They offer flexible, integrated and user-friendly freight solutions including real-time tracking, electronic proof of delivery and traffic-aware routing, with a focus on personalised service for businesses of all sizes.
Mainstream has developed its own freight and warehouse management systems over 25 years and emphasises transparency, community support and sustainability. Their commitment extends to initiatives like co-branded transport partnerships and donations including a St. John’s Health Shuttle serving rural Northland communities.
Project Challenges
Mainstream approached Storepro with a clear goal of establishing a new high-density 3PL warehouse. They faced significant challenges:
- 3-month timeline – The warehouse needed to be operational within an exceptionally tight timeframe
- 10,000+ pallet positions – Minimum capacity required to ensure commercial viability
- Investment protection – Previous racking projects had suffered from inadequate protection and high maintenance costs
The compressed timeline presented the greatest challenge. Standard warehouse fitouts involving building consent, procurement, installation and compliance certification typically require four to five months. Mainstream needed a partner who could deliver faster without compromising safety or quality.
OUR SOLUTION
The Storepro Solution
After a detailed site consultation and needs assessment, Storepro proposed a solution tailored to Mainstream’s operational requirements:
VNA pallet racking working with Aislemaster articulated forklifts to maximise pallet capacity – achieving 40% more storage than conventional systems
Frame end and post protection throughout the warehouse to reduce racking damage and minimise repair costs
Detailed installation schedule allowing parallel workstreams for building consent and racking installation to meet critical deadlines
The VNA system design featured back-to-back configuration with aisles reduced by up to 1.5 metres compared to standard layouts. This achieved over 55% floor utilisation while maintaining the excellent stock rotation capabilities essential for 3PL operations.
SOLUTION & OUTCOME
- 639 bays of pallet racking
- 10,674 pallet racking beams
- 693 frames ranging from 10m to 13.5m
- Compliance checks and safety features as per NZ standards.
The work was completed ahead of schedule and under budget – a testament to meticulous planning and flawless execution. Every component was positioned to support Mainstream’s specific 3PL workflows.
The Outcome
The result was a fully optimised storage system delivering measurable benefits:
Improved operational efficiency
The VNA systems enabled faster picking and inventory access, boosting throughput for Mainstream’s time-sensitive logistics operations. Staff productivity increased through logical layout design and reduced travel distances.
Cost savings
By optimising warehouse space and eliminating the need for additional facilities, VNA racking lowered operational costs while maintaining high inventory turnover crucial for 3PL profitability.
Investment protection
Mainstream’s warehouse undergoes 6-monthly audits by Storepro’s in-house inspection team. The comprehensive frame protection has dramatically reduced repair and maintenance costs compared to previous installations.
From the very first enquiry communication with Sam, Storepro have demonstrated the ‘partnership approach’ that we value. All departments that we have dealt with have been well briefed on the project, leading to ease of communication and understanding on the progress.
The installation team have worked in a safe and professional manner to date and are a well-trained team, responsive to any change in circumstances at short notice.
Michael Van Staden
National Logistics Manager, Mainstream New Zealand
STORAGE SOLUTIONS PROVIDER
Why choose Storepro?
Tens of thousands of customers can’t be wrong. As the largest 100% NZ owned and operated business in our industry, at Storepro we bring a deep understanding of your warehousing needs, wants and goals.
We design, engineer and build all of our solutions right here in NZ. But we don’t just build warehouse racking – we build relationships too. We listen to your needs, develop bespoke solutions, and support you all the way.
Contact us
100% New Zealand owned and operated, at Storepro we understand the needs, values and preferences of Kiwi businesses, and design, engineer and build all our solutions right here in NZ.
Get in touch with our friendly team today, whether in store (Auckland and New Plymouth), by phone or email, or by filling in the form.