What is the difference between traditional crate storage and LT Storage systems?

The main difference between traditional crate storage and LT Storage systems lies in their approach to space utilisation and automation. Traditional methods rely on manual handling, pallet-based systems, and rack storage that require significant floor space and height clearance. LT Storage is a patented compact storage crate system that places stacks directly on the warehouse floor in consecutive rows, maximising storage density whilst requiring minimal ceiling height. This automated approach eliminates many manual processes and optimises floor area usage compared with conventional storage methods.

What exactly is traditional crate storage and how does it work?

Traditional crate storage involves manual stacking, pallet-based systems, and rack storage that require workers to physically handle plastic crates throughout the storage process. These conventional methods typically use warehouse racking systems, where crates are placed on pallets and stored in multi-level rack structures, or simple floor stacking, where workers manually arrange crates in designated areas.

The operational characteristics of traditional storage include significant space requirements for aisles between racks, high ceiling clearances for forklift operations, and substantial manual labour for moving, stacking, and retrieving crates. Workers must physically lift and position each crate or stack, which creates bottlenecks during peak operations and increases the risk of workplace injuries.

These systems often struggle with space efficiency because they require wide aisles for equipment access and cannot utilise low-ceiling areas effectively. The manual nature of traditional storage also makes it difficult to maintain consistent throughput, as processing speeds depend entirely on worker availability and physical capabilities.

How does LT Storage differ from conventional crate storage methods?

LT Storage uses automated floor-based storage with a modular design that eliminates the need for traditional racking systems or extensive manual handling. This patented technology places crate stacks directly on the warehouse floor in consecutive rows, using automated systems to manage the movement and positioning of plastic crate stacks throughout the storage area.

The system’s modular approach allows for flexible configuration based on facility layout and operational requirements. Unlike traditional methods that require fixed rack installations and predetermined aisle widths, LT Storage can be adapted to various space constraints and reconfigured as needs change.

The automated handling capabilities mean that workers no longer need to manually lift and position heavy crate stacks. Instead, the system manages the movement of stacks automatically, reducing physical strain on workers and enabling consistent processing speeds regardless of staffing levels. This automation also provides better inventory control and reduces the risk of damage from manual handling errors.

What are the main space and capacity advantages of LT Storage?

LT Storage maximises floor area utilisation and works in low-ceiling environments, typically requiring only 650 mm of space above the stack height. This compact storage crate design allows facilities to achieve higher storage density compared with traditional rack systems that need significant clearance for forklift operations and safety requirements.

The floor-based approach eliminates the need for wide aisles between storage rows, as the automated system can access stacks without requiring space for manual equipment manoeuvring. This means more of the available floor area can be dedicated to actual storage rather than access routes.

The system’s flexibility extends to unusual facility layouts, including mezzanine levels and areas with height restrictions where traditional storage methods cannot operate effectively. This adaptability allows businesses to utilise previously unusable spaces and increase their overall storage capacity without expanding their facility footprint.

Which storage system is better for different production environments?

LT Storage suits high-volume operations with space constraints, whilst traditional storage may work for smaller facilities with ample space and lower throughput requirements. The choice depends on factors including facility size, ceiling height, production volume, labour costs, and long-term operational goals.

Facilities with height restrictions, limited floor space, or high labour costs benefit significantly from LT Storage’s compact design and automation capabilities. The system works particularly well in food production environments, where hygiene requirements and consistent throughput are priorities.

Traditional storage remains viable for operations with low crate volumes, existing rack infrastructure, and sufficient manual labour resources. However, businesses experiencing growth, facing labour shortages, or dealing with space limitations should consider the long-term advantages of automated compact storage crate systems.

When evaluating options, consider factors such as current manual handling costs, space utilisation efficiency, future expansion plans, and the need for consistent processing speeds. Investment in automated storage typically provides returns through reduced labour costs, improved space efficiency, and enhanced operational reliability.