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Everten Supplies — absorbing e-commerce growth without moving warehouse

An online kitchenware retailer at the limit of a 1,056 m² building put 2,759 storage locations into 50 m² of floor, cut mispicks by half, and stopped looking for a new facility.

Hand lifting a boxed part out of a Storeganizer textile pocket

18

Storeganizer bays

2,759

storage locations created

50 m²

floor area used

−50%

mispick rate

The situation

Project profile
Industry E-commerce retail
Application Online kitchen and homeware fulfillment
System Storeganizer high-density textile pocket columns in existing pallet rack
Source Results as reported by the operation and its Storeganizer manufacturer, KTP conTeyor

Everten Supplies sells kitchenware online, and by the time warehouse manager Kelvin Plain joined in 2017 the business was outgrowing its 1,056 m² warehouse. Growth was fast, the product range kept expanding through acquisitions, and a large share of the stock was small items sitting on conventional shelving that was never designed for them.

The symptoms were the familiar ones and they compounded each other: items took longer to put away, got pushed into the next location, got interchanged, got mixed up. That produced stock discrepancies that took time to unpick and mispicks that reached customers. The company was at the limit of its capacity and already exploring options to move out.

What was installed

Eighteen bays were installed, deliberately combining pocket sizes — small, medium and large — to generate 2,759 optimised storage locations. Individualised pockets removed the root cause of the mixing: an item can no longer be pushed into the next location, because there is no next location to push it into.

Kelvin Plain was, by his own account, hesitant at first. That is worth including in a case study, because scepticism about textile storage is common and the operators who report the largest gains are frequently the ones who started out unconvinced.

Diagram of the Storeganizer universal suspension rail on a pallet rack beam and columns hung up to four rows deep
Columns hang from a suspension rail built to the existing beam profile, up to four rows deep, with front rows rolling aside by hand.

Reported results

Measure Before After
Storage locations Conventional shelving locations 2,759 across 18 bays, mixing three pocket sizes
Share of total stock lines in that footprint 10% 25%
Floor area used Shelving across a larger area 50 m²
Pickers required in that area 3 full-time 1 full-time equivalent
Mispick rate Baseline Down 50%
Relocation Actively exploring a move Postponed; growth absorbed in place

“Before, we had three full-time pickers in that area. Storeganizer helped to bring this down to one full-time equivalent, while the mispick rate dropped by 50%.”

— Kelvin Plain, Warehouse Manager, Everten Supplies

The strongest number here is the one that never appears on an invoice: the relocation that did not happen. A move to a larger facility carries fit-out, new racking, downtime, and a rent increase that continues for the length of the lease. Deferring it by converting 50 m² of an existing building is a different order of expenditure entirely.

The share of stock lines held in that footprint rising from 10% to 25% is the density figure stated honestly — not a claim about the whole warehouse, but a measurement of what one converted area now carries.

Clear Storeganizer pockets with label holders creating high-density pick faces in pallet rack
Individual labelled pockets: an item cannot be pushed into the next location, because there is no next location to push it into.

What this means for a US operation

Every warehouse is different, and a result reported elsewhere is evidence rather than a forecast. These are the transferable parts:

  • Mixing pocket sizes in one installation is what produces high location counts. Everten used small, medium and large together to reach 2,759 locations.
  • Discrete addressing fixes mixing, not just density. The stock-discrepancy problem and the mispick problem were the same problem.
  • Compare a conversion against the cost of moving. For a growing e-commerce operation, that is almost always the real alternative.

The measured averages behind these cases — around 40% more usable space, 42% less travel time and 26% better picking efficiency — come from independent research at the University of Leuven, Belgium (2013), comparing Storeganizer with conventional rack and shelf. To see what the same arithmetic produces in your own bay, use the Storeganizer Designer or ask us to run the numbers with you.

Why this inventory profile suits pocket columns

The transferable part of any case study is the profile, not the logo. These are the characteristics that made this operation a good candidate — and they are the ones worth checking against your own inventory before you consider a conversion.

📦

Small items, many lines

Online kitchenware and homeware ranges are dominated by small SKUs that conventional shelving handles badly.

📈

Growth arriving faster than space

Converting an existing zone is measured in weeks; relocating is measured in months and in rent for the length of a lease.

❌

Items migrating between locations

An individual pocket per SKU physically prevents the pushing and mixing that creates stock discrepancies.

🧰

Mixed item sizes in one range

Small, medium and large pockets in the same installation produced 2,759 locations in 50 m².

Diagram comparing 3 storage locations in a pallet position with 42 locations in Storeganizer pocket columns
How 2,759 locations fit into 50 m² — the same footprint, addressed at item scale instead of pallet scale.

How a conversion like this runs

Four steps, and none of them involve construction. The sequence matters: the slotting analysis comes before the measurement, and the count comes before the order.

1

Profile the SKUs

We look at item size, stock depth and order frequency for the zone in question — the three properties that decide whether a pocket is the right home for a part.

2

Measure the bays

Inside width, inside depth, clear height and beam profile. The suspension rail is then manufactured to those dimensions.

3

Configure and count

Pocket sizes are selected per SKU group and the location count is calculated before anything is ordered.

4

Install and slot

Columns hang from existing beams in an operating warehouse — no drilling, no anchoring, no permit drawing — then stock is slotted in.

We handle all four in the United States, including the install. Because the system is maintenance free — no motors, no controls, no annual service contract — there is nothing scheduled after handover.

Questions about this project

How many storage locations did Everten create?
2,759 locations across 18 bays, combining small, medium and large pockets in the same installation.
How much stock does that footprint hold?
The 50 m² now occupied by Storeganizer previously held about 10% of overall stock; it currently accommodates around 25% of stock lines.
What happened to the mispick rate?
Everten reported the mispick rate dropped by 50%, and that the area went from three full-time pickers to one full-time equivalent.
Did Everten still need a bigger warehouse?
The relocation was postponed. The company had been exploring a move out of its 1,056 m² warehouse and was able to absorb continued growth in place instead.

Could your rack do this?

Tell us the bay dimensions and the SKUs giving you trouble. We will come back with a configuration, a location count and an honest view of whether a conversion is worth it.

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