Maximizing Warehouse Efficiency: How Dollarama Achieved Over 90% Storage Utilization with 3D Pushback Racking
CLIENT
Dollarama is a leading dollar store retailer with over 1,600 total stores in operation. It is serviced by three existing distribution centres totalling over 1,250,000 square feet.
CHALLENGES
With high growth continuing, Dollarama needed additional warehousing to meet the demands of the new stores. They also had to develop a high-density layout to ensure they could maximize the use of the space they built.
“As the rack manufacturer and integrator for this project, working with 3D Storage Systems was for us very easy and pleasant. We appreciate the quality of the product; always a perfect fit and very easy to install. We value their customer service, great teamwork in coordinating production and freight, and their ability to meet the expected project milestones ……to summarize: ‘peace of mind. ‘”
SOLUTION
In 2016, Dollarama broke ground on a new state of the art 500,000 square foot distribution center. Working in conjunction with Etalex, a leading rack manufacturer based in Montreal, and 3D Storage Systems, over 53,000 pallet positions of 6 deep pushback were installed in the new facility.
Dollarama has been a longtime user of 3D’s low profile pushback, with the first installation dating back to 2003. Historically Dollarama had used drive-in racking to store material within their warehouse facilities. However, they were finding that honeycombing was leading to space utilization rates lower than 70%. By switching to pushback, they were able to still achieve a high-density layout but also increase the utilization rate to over 90% (see our section on Pushback Justification for more detail on this topic). Since 2003 Dollarama replaced a number of the drive in rack systems with pushback to increase their storage capacity.
“The Dollarama Project showcases our expertise in high-density storage solutions. Our pushback racking system optimized space efficiency, ensuring seamless inventory flow and maximizing pallet positions. A great success for both teams!”
PRODUCT SPECIFICATIONS
8,946 lanes of 3D’s 6 Deep Low-profile pushback, complete with linked carts, welded steel shafts and lane full indicators
Reinforced roll formed frames with structural steel bullnose protection and structural steel load beams
- Over 90% Occupancy rates
- 85% more storage density compared to standard selective rack
- Over 100,000 square feet saved versus drive-in rack
At 3D Storage Systems, we specialize in high-density storage solutions that help businesses like Dollarama maximize space, improve efficiency, and reduce costs. Whether you’re expanding an existing facility or designing a new warehouse, our innovative pushback racking systems provide the reliability and performance you need.
Ready to optimize your storage capacity? Contact us today to discuss your project.