E-commerce fulfillment centers have very different racking needs compared to traditional warehouses. The focus is speed (picks per hour), not just storage density. Here's how to set up racking for e-commerce operations based on our experience with 50+ fulfillment centers in Bhiwandi, Navi Mumbai, and Pune. What Makes E-Commerce Warehousing Different | Factor | Traditional Warehouse | E-Commerce Fulfillment | |--------|---------------------|----------------------| | Order size | Full pallets | 1-3 items per order | | SKU count | 50-500 | 5,000-100,000+ | | Picks/day | 50-200 pallets | 5,000-50,000 items | | Speed requirement | Same-day replenishment | Same-hour picking | | Return handling | Minimal | 15-30% of volume | | Storage unit | Pallet | Bin/carton/each | The E-Commerce Racking Solution Zone 1: Bulk Reserve Storage (Pallet Racking) Full pallets of stock that replenishes the picking area. Standard selective pallet racks work here. - Type: Selective pallet racks, 3-5 levels - Capacity: 1,000-2,000 kg per level - Access: Forklift operated - Purpose: Store bulk inventory received from suppliers Zone 2: Pick Modules (Multi-Tier Racking with Bins) This is where the magic happens. Multi-level racking with bin locations for each SKU: - Type: Multi-tier racking with
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