Does Your Warehouse Need a Mezzanine? The Pros and Cons Explained
October 17, 2024
DOES YOUR WAREHOUSE NEED A MEZZANINE?
In today’s industrial landscape, where space is at a premium, warehouse managers are constantly seeking innovative ways to maximize their available square footage. With the industrial vacancy rate in cities like Montreal, it's no wonder many businesses are asking the same question: Should we install a mezzanine?
At Meriton Industries, with over 20 years of experience serving hundreds of warehouses and distribution centres, we’re often asked to compare two popular options: Mezzanines and Pallet Racking.
Both have their unique advantages, but they serve different purposes. Here’s an honest comparison to help you decide which is best for your facility.
PALLET RACKING: THE PROS AND CONS
Pros of Pallet Racking
1. Purpose-Built for High-Density Storage
Pallet racking systems are specifically designed to optimize pallet storage based on quantity of SKU’s and inventory requirements, making them ideal for high-density storage. There’s a lot of system out there for different industry needs.
2. Economical
Pallet racking is a cost-effective storage solution. Even our most expensive racking systems, such as Push-Back Racking, are significantly less than the $1,000+ per pallet position with a mezzanine.
3. Flexibility
Pallet racking is incredibly adaptable. As your business grows, your racking system can evolve with it, allowing for reconfigurations, expansions, or even upgrades to more advanced systems.
Cons of Pallet Racking
1. Space Requirements
If you need additional production space or picking for small parts then you should consider a mezzanine.
2. Space Constraints
If your available space is above a production area, pallet racking might not be viable, making a mezzanine your only option.
3. Incompatibility with Small Parts Storage
For warehouses that need to store and pick small parts, pallet racking can be inefficient since pickers have to share aisles with forklifts.
MEZZANINES: THE PROS AND CONS
Pros of a Mezzanine
1. Utilize Unused Space
Mezzanines allow you to capitalize on vertical space, effectively doubling your floorspace. Even if a full-scale mezzanine isn’t practical, a smaller installation can still add significant value by providing additional workspace.
2. Production / Picking Space
The best use of a mezzanine from an operational standpoint is for additional production space or parts picking. This can provide additional square footage when the building clear-height allows an additional level to be added.
3. Versatility
Mezzanines can be used for offices, lunchrooms, or conference spaces, freeing up ground-level space for more critical activities like storage or production.
Cons of a Mezzanine
1. Higher Cost
Mezzanines can be expensive, costing between $65 and $75 per square foot. This translates to over $1,000 per pallet position—far more than the cost of pallet racking.
2. Inefficient for Storage
Mezzanines typically offer lower storage density compared to racking systems. A 20’ x 50’ mezzanine platform might only store 60 pallets, making it less efficient for high-density storage needs.
3. Inefficient Material Handling
Moving goods onto and off a mezzanine is often labor-intensive and time-consuming, requiring coordination between forklift operators and workers on the mezzanine.
4. Difficulty in Relocation
Mezzanines are usually custom-built for specific spaces and are not easily relocated. If you have a short-term lease, the cost of installing a mezzanine might not be justifiable.
MERITON'S OPINION
Phil Anderson weighs in, “A mezzanine is very inefficient for storing and retrieving pallets. If you’re looking for ways to store more pallets, and you’re considering a mezzanine, talk to one of our team, we may be able to bring you ideas that will be more efficient.”
KEY TAKEAWAY
Pallet racking is an efficient, economical solution for high-density pallet storage, while mezzanines are ideal for creating additional workspace by utilizing vertical space. Both have their place in warehouse design, but the right choice depends on your specific needs.
If you’re still unsure which option is best for your facility, we’re here to help! Contact us at info@meritonindustries.com or give us a call at 514-457-5358 to discuss your next steps.