How much space does an LT Storage system require for plastic crate storage?

An LT Storage system typically requires just 650 mm of vertical clearance plus the height of your crate stacks, making it suitable even for low-ceiling warehouses and mezzanine installations. The system places crate stacks directly on the warehouse floor in consecutive rows, maximising storage density while requiring minimal floor space compared with traditional racking systems. This modular approach allows facilities to achieve significantly higher storage capacity within their existing footprint.

What exactly is an LT Storage system and how does it use warehouse space?

LT Storage (Logistic Tote Storage) is a patented storage system that places plastic crate stacks directly on the warehouse floor in consecutive rows, eliminating the need for traditional racking infrastructure. This modular design maximises floor area utilisation by storing crates in a dense, organised pattern that can be easily reconfigured as storage needs change.

Unlike conventional storage methods that require aisles between every rack section, LT Storage arranges stacks in continuous rows that optimise space efficiency. The system works with an automatic crate stacker that can precisely position and retrieve crate stacks, ensuring smooth material flow while maintaining high storage density. This approach transforms warehouse floors into highly efficient storage areas without requiring permanent structural modifications.

The modular nature of the system means you can start with a smaller installation and expand as needed. The system integrates seamlessly with existing warehouse management systems and can accommodate various crate sizes and weights, making it adaptable to different operational requirements.

How much floor space does an LT Storage system actually require?

The floor space required depends on your storage capacity needs, but LT Storage typically uses 30–40% less floor area than conventional racking systems for the same storage volume. Minimum installations can fit within areas as small as 50 square metres, while larger operations may utilise several hundred square metres.

Access areas around the system perimeter require approximately 1.5–2 metres for safe operation of the automatic crate stacker and for maintenance access. The system does not need internal aisles between storage rows, which is where significant space savings occur compared with traditional warehouse racking that requires aisle access throughout.

When planning floor space, consider that the system can be configured in various layouts to fit irregular warehouse shapes. The modular design allows for L-shaped, U-shaped, or linear configurations, making it possible to utilise awkward spaces that might otherwise remain unused. This flexibility ensures optimal use of available floor area regardless of your warehouse layout constraints.

What are the height requirements for installing an LT Storage system?

LT Storage requires a minimum ceiling height of 650 mm above your tallest crate stack for safe operation of the automatic crate stacker. For standard 600 mm-high plastic crates stacked four high (2.4 metres), you will need approximately 3.05 metres of total ceiling height.

This low height requirement makes the system particularly valuable for facilities with space constraints. Many warehouses with ceiling heights of just 3.5–4 metres can accommodate LT Storage effectively, including mezzanine installations where traditional high-bay storage systems would not fit.

The system includes safety clearances for equipment operation and maintenance access. Overhead obstacles such as lighting, sprinkler systems, or ventilation equipment need to maintain the minimum 650 mm clearance above the highest point of operation. This requirement is typically much lower than for conventional automated storage systems, making LT Storage suitable for retrofitting existing buildings without major structural modifications.

How does LT Storage maximise capacity compared with traditional storage methods?

LT Storage achieves higher storage density by eliminating internal aisles and placing crate stacks directly on the floor in consecutive rows. Traditional racking systems lose 40–50% of floor space to aisle access, while LT Storage dedicates nearly all floor area to actual storage.

The consecutive-row arrangement means crates are stored with minimal gaps between stacks, maximising the number of storage positions within any given footprint. An automatic crate stacker retrieves specific stacks as needed, so every position remains accessible without requiring permanent aisle space.

This approach typically increases storage capacity by 60–80% compared with conventional methods in the same floor area. The system also serves as a buffer to balance incoming and outgoing crate flows, reducing bottlenecks in production areas. By concentrating storage in a smaller footprint, facilities can dedicate more space to value-adding activities such as production, packing, or quality control.

The space efficiency of LT Storage makes it particularly valuable for facilities facing expansion constraints or high property costs. Rather than requiring additional warehouse space, the system often enables operations to handle increased throughput within their existing buildings while improving overall workflow efficiency.