Industry: Manufacturing (Paints & Coatings)
Project Type: Full Warehouse Pallet Racking Fit-Out
Hamilton, New Zealand
Completion Date: August 2025
Who Are WATTYL
Client Overview
Wattyl is a leading manufacturer of paints and coatings, serving both the Australian and New Zealand markets.
When the business opened its new Hamilton distribution centre, it required a large-scale storage system capable of managing mixed pallet standards, meeting compliance requirements, and ensuring a safe, future-ready warehouse layout from day one.
Project Challenges
Wattyl engaged Storepro early in the design phase to ensure its warehouse layout would support operational efficiency and regulatory compliance.
The project required a balance between space optimisation, safety, and flexibility for future expansion.
Load and capacity certainty – validating maximum pallet weights (typically 900–1000 kg) and allowable pallet counts per bay.
Mixed pallet sizes – accommodating both NZ standard (1200 × 1000 mm) and AU standard (1165 × 1165 mm) pallets within the same system.
Vertical clearances – ensuring safe stacking of two loaded pallets per bay.
Racking depth and aisle widths – balancing NZ’s 900 mm depth with dual-pallet requirements while maintaining clear forklift access (~3080 mm post-overhang).
Dangerous Goods compliance – designing a DG storage area that met regulatory requirements while maintaining consistency across the site.
Future readiness – factoring in compatibility with material handling equipment, turning circles, and potential in-rack sprinkler integration.
How Storepro Overcame the Challenges
Despite the complexity of the brief, Storepro worked closely with Wattyl’s project and operations teams to turn these requirements into a clear, practical design. Through early engagement, detailed load assessments, and proactive coordination with compliance specialists, the team ensured every technical and regulatory challenge was resolved before installation began, laying the foundation for a seamless fit-out phase.
OUR SOLUTION
The Storepro Solution
Working in close partnership with Wattyl’s project team, Storepro developed a solution that achieved the operational objectives while meeting every compliance standard.
403 bays of selective pallet racking across multiple configurations with 5–8 beam levels plus ground storage.
Dual-pallet compatibility built into rack depth and spacing to accommodate both NZ and AU pallets.
Load-rated beams (2,000 kg per pair) providing safe support for up to two pallets per bay.
Dedicated Dangerous Goods area – 1,080 pallet positions and 206 pick levels, designed for compliance adaptability.
Optimised aisle layout with verified clearances (~3080 mm post-overhang) for safe forklift manoeuvring.
Comprehensive safety integration including 368 post protectors, 84 end-frame barriers, and load signage throughout.
Full compliance pack – PS1–PS4 producer statements supplied for building consent submission.
Managing The Project
While the design and specification stages were clear, the installation required detailed coordination to maintain programme efficiency.
Key project challenges included:
Container scheduling – managing delivery of eight 40-foot containers to maintain continuous workflow.
Tight timeframe – completing a full installation within five weeks alongside ongoing site works.
Live environment – adhering to strict health and safety controls, with inductions and staging around other contractors on site.
Through proactive planning and communication, Storepro delivered the project on time and without disruption to the broader site operations.
SOLUTION & OUTCOME
Work Carried Out
We delivered a comprehensive warehouse storage solution tailored to Wattyl’s operational and safety needs, managing the entire fit-out from structural design to final installation and compliance.
Supply, delivery, and installation of 403 bays of seismic-compliant racking.
Total capacity: 5,660+ pallet positions (4,580 main + 1,080 DG).
796 picking levels integrated for fast-access stock.
Installation of barriers, post protection, signage, and full certification.
Completed in five weeks, fully aligned with factory lead times and consent requirements.
The Outcome
Wattyl’s new Hamilton warehouse now operates with:
Optimised storage capacity – maximising usable space across both pallet types while ensuring safe DG segregation.
Improved workflow efficiency – clear aisles and consistent beam spacing to support seamless movement and access.
Built-in compliance – seismic-rated structure, PS1–PS4 documentation, and provision for future fire-safety integration.
The new racking layout has transformed how we operate. We’re making better use of space, and our team can work more safely and efficiently every day.
Operations Team
Wattyl 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.