Eliminate 65% of deadhead picker travel time and multiply throughput using DEXION RACKING dynamic carton flow, multi-tier shelving, and integrated pick-to-light engineering.
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Optimized Multi-Order Picking Systems
Combine high-density pallet buffers above with continuous ergonomic gravity-fed carton lanes below.
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Vertical Volume Utilization
Multiply floor space threefold with structural mezzanine tiers purpose-built for fast-moving split-case picks.
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WMS & Robotic Automation Ready
Precision-tolerance steel framing tailored for AMR carts, put-walls, and automated sorting conveyor loops.
Send an InquiryWhy are global supply chain directors, fulfillment operations managers, and distribution architects moving away from discrete order picking to high-efficiency batch fulfillment workflows?
In conventional discrete order picking, up to 70% of an operator's shift is lost to unproductive walking time—traversing massive warehouse aisles to retrieve a single item for a single order slip. DEXION RACKING engineers solve this structural bottleneck by designing comprehensive Batch Picking Solutions that aggregate identical SKU quantities required across tens or hundreds of distinct orders into a unified, single-cycle pick itinerary.
By pairing high-density Carton Flow Live Storage beds, multi-tier structural mezzanine picking towers, and put-to-light sortation walls, operators pick the aggregated item totals in one consolidated pass. These consolidated bulk items are then swiftly separated into individual orders at high-speed downstream consolidation packing stations. This systemic structural reorganization yields massive operational gains:
Engineered order fulfillment: high-density batch picking configurations deployed across European hubs
Every inventory velocity profile demands a matching structural picking foundation. Discover how DEXION RACKING matches racking mechanics to batch sorting methodologies.
Dynamic Flow Combines heavy bulk pallet reserve storage in upper levels with multi-lane dynamic roller beds at floor level. Enables independent FIFO stock replenishment from the rear without ever disrupting front-face batch picking operators.
Split-Case Picking Precision cold-rolled galvanised steel shelving specifically designed for high-SKU density split-case fulfillment. Modular dividers and bin containers configure smoothly for mobile multi-order batch pick carts and pick-to-light hardware.
Multi-Tier Cube Multiply available picking footprints by up to 300% by exploiting the building's clear vertical clearance. Engineered walkways, integrated spiral chutes, and carton conveyor feeds enable zonal batch pick operations across multiple elevated tiers.
Semi-Automated Goods-to-Person vertical lift modules (VLMs) delivering batched SKU totes directly to ergonomic waist-height picking windows. Ideal for ultra-compact pharmaceuticals, micro-electronics, and high-value slow-moving batch consolidation.
Ultra-Dense Buffer Motorized mobile pallet racks eliminate fixed aisles, holding reserve cases and pallets at double the density. Perfect for high-density buffer stock staging directly adjacent to batch picking modules and outbound sortation hubs.
Sort & Pack Zone Modular rear-open pigeon-hole racking modules equipped for bi-directional order assembly. Batch-picked bulk totes are loaded into back slots, while packing specialists consolidate, inspect, and label discrete client cartons on the front face.
Making data-driven capital investments requires a rigorous side-by-side engineering evaluation of workflow dynamics and structural footprints.
When operations face surge seasons, expanding SKU counts, and tightened same-day delivery SLAs, discrete picking breaks down under labor shortages and traffic bottlenecks. The table below illustrates the concrete structural and productivity transformation achieved by implementing a DEXION RACKING Batch Picking Solution:
| Operational Metric | Standard Discrete Picking | DEXION RACKING Batch Solution |
|---|---|---|
| Picker Shift Travel Time | 60% – 70% of total labor time spent walking | Under 18% (consolidated single-loop traversal) |
| Average Picking Throughput | 50 – 80 order lines / hour / operator | 240 – 420 lines / hour / operator |
| Stock Face Utilization | Deep single aisles with scattered SKU access | High-density gravity carton flow beds |
| Replenishment Interference | High: Pickers and reach trucks share aisles | Zero: Continuous rear loading, forward picking |
| Automation Compatibility | Limited (manual paper or RF barcode scans) | Full (Pick-to-Light, AMR, Put-Walls, WMS) |
| Structural Safety Standard | Varies widely | Fully certified to European Standard EN 15512 |
Integrated picking environment: Combining high-level pallet reserves with low-level batch flow picking
Procurement directors and supply chain leaders are navigating fundamental structural changes. Here are the core technological and supply trends dominating 2026 and beyond.
Modern batch picking no longer isolates human pickers with heavy pushcarts. The fastest-growing procurement trend is the integration of collaborative AMRs that travel autonomously alongside pickers down racking aisles. DEXION RACKING manufactures rack bay apertures and floor rail tolerances with millimeter-level laser precision, providing seamless navigation tracks for LiDAR-guided robotics.
Procurement teams are prioritizing physical storage layouts that adapt to AI-powered Warehouse Execution Systems (WES). AI engines analyze incoming streaming orders to dynamically formulate batch runs based on real-time SKU affinity and physical proximity, drastically cutting pick wave cycle times and ensuring hot-selling seasonal goods occupy prime pick planes.
With global industrial land lease costs remaining at historic highs, facility managers are building up rather than out. High-cube pick towers that span 2 to 4 vertical mezzanine tiers combine carton flow live storage, central spiral chutes, and overhead carton accumulation conveyors, tripling pick capacity within an identical real estate footprint.
Corporate ESG directives are reshaping warehouse procurement. Leading enterprises are eschewing complete teardowns in favor of retrofitting existing selective racking uprights with modular carton flow roller beds and energy-neutral gravity feeds. High-grade European steel with end-to-end mill certification reduces embodied carbon while boosting throughput.
Urban micro-fulfillment centers require ultra-dense, ultra-fast batch picking to fulfill grocery and omnichannel orders within 30-minute windows. Compact dynamic shelving systems with color-coded Pick-to-Light guides are becoming standard procurement requirements for fast-response urban delivery hubs.
As picking intensities increase, rack load stress and human-equipment interactions multiply. Buyers demand stringent conformity to EN 15512 design standards and mandatory annual EN 15635 rack safety inspections, ensuring that high-throughput dynamic facilities remain safe, certified, and compliant over decades of heavy service.
Decades of structural engineering mastery, European manufacturing standards, and complete turnkey fulfillment lifecycle management.
At DEXION RACKING, we do not simply sell steel components. We engineer high-performance logistical systems tailored to your specific SKU profiles, carton weight ranges, building geometries, and growth roadmaps. Global procurement officers choose us for four fundamental reasons:
Certified installation and precision commissioning: Large-scale European distribution center execution
A rigorous, engineering-driven execution roadmap mitigating procurement risk, ensuring safety certification, and accelerating on-time site commissioning.
We analyze order velocity curves, SKU physical dimensions, pallet weights, and order batch profiles to design optimum pick faces.
Our engineers calculate static load capacities, structural column grids, and egress safety paths strictly aligned with EN 15512.
Roll-formed uprights, beam assemblies, and dynamic gravity roller tracks are manufactured under ISO quality controls with full traceability.
Certified DEXION RACKING installation specialists erect, laser-align, and load-test your dynamic batch picking infrastructure.
We provide annual statutory rack safety inspections, beam load documentation, damage repairs, and system expansion services.
True supply chain sustainability begins with structural efficiency. By utilizing vertical cube volume with DEXION RACKING batch picking towers and gravity-fed live carton storage, warehouses reduce their operational footprint, minimize lighting and heating energy per order handled, and avoid the immense carbon expenditure of constructing new buildings. Engineered with 100% recyclable high-strength European steel, our systems deliver multi-decade service life.
Answers to the critical structural, operational, and financial questions global buyers, 3PL directors, and engineering leads ask when planning batch picking implementations.