Warehouse consultants
Our expert warehouse consultants are here to help you cut costs, deliver better service, and maximise efficiency.
INTRODUCTION
Specialist warehouse consultants
Warehouses are a supply chain inefficiency – a point where material flow stops and non-value costs begin to build. Reducing those costs can mean anything from evaluating the warehouse design and layouts and improving processes to introducing mechanisation or, where viable, full automation.
Whatever the challenge, our experienced warehouse consultants can help you optimise performance and unlock greater efficiency. From strategic network reviews and capacity planning to warehouse design, operational improvement and automation business cases, we help organisations create safer, more productive and more cost-effective warehousing operations.
Projects delivered
300+
Independent
Advice
Established
Since 2014
Trusted by
200+ clients
TRUSTED BY LEADING ORGANISATIONS
WAREHOUSING
The challenges of warehousing
Every supply chain requires storage at some stage, making efficient warehousing, handling, and inventory management essential to overall performance.
Whether your warehouse supports your manufacturing, retail, or e-commerce operations, the goal is the same – stay organised, efficient, and minimise time and cost. This can be achieved by optimising layouts for faster picking, upgrading MHE for smoother flow, and refining inventory to free up space.
As customer demand shifts supply chains toward faster, more frequent, lower-volume deliveries, warehouse pressures intensify. Rising throughput speeds are exposing operational weaknesses that drive up costs and erode service levels.
Our warehousing consultants are here to help you get your warehouse operations back on track.
WAREHOUSE CONSULTANTS
Here to meet your challenges
Successful warehouse design requires both technical expertise and real-world operational experience. Too often, facilities are designed on a ‘roughly right’ basis, or by CAD engineers without accounting for the realities of daily operations. This roughly right approach can often lead to being exactly wrong.
Our team has the technical ability and operational experience to ensure that warehouse designs work in practice as well as on paper, that all options are thoroughly explored, and help secure stakeholder buy-in for major changes.
WAREHOUSE CHALLENGES
Common warehouse challenges we solve
Whether the challenge relates to warehouse design, operational efficiency, inventory optimisation or relocation planning, our warehouse consultants provide practical, independent advice tailored to each organisation’s requirements.
Capacity constraints
Warehouse operating at or near maximum storage capacity.
Productivity issues
Low picking rates, excessive travel and inefficient workflows.
Inventory accuracy
Stock discrepancies impacting service and planning.
Warehouse relocation
Planning and executing warehouse moves and consolidations.
Service performance
Customer service levels below target.
Warehouse design & layout
Inefficient use of space and handling equipment.
CASE STUDIES
Recent warehouse projects
Examples of warehouse projects delivered by our consultants.
Aerospace warehouse design and site consolidation
- 440,000 sq ft
- 3 sites
- 5 design stages
PTL Co developed the warehouse design for a 440,000 sq ft aerospace facility, supporting the consolidation of three operations into one integrated site.
Warehouse design for a medical products manufacturer
- 50,000 sq ft
- 4,400 shelf pick locations, 1,800 reserve pallets
- 3 operations consolidated
PTL Co developed an expanded warehouse design for a medical products manufacturer, supporting multi-site consolidation, improved flow and future growth planning.
Warehouse outsourcing for a subscription business
- 2m packs despatched annually
- 6,000 stock locations
- 16-week implementation and stabilisation
PTL Co managed an 11-week outsourcing tender for a subscription fulfilment business despatch, assessing providers against recurring peaks, strict cut-offs and time-critical service.
SERVICES
Warehouse consultancy services
Our warehouse consultancy offering covers a range of specialist disciplines. Explore the services below to learn more about how we support warehouse operations and distribution facilities.
Warehouse design
- Warehouse layout design
- Storage & capacity planning
- Automation & equipment selection
Whether reconfiguring an existing site or creating a new one, our experts support you from initial design through fit-out, commissioning, and go-live – covering everything from simple APR racking to fully automated facilities.
Inventory management
- Inventory policy development
- Safety stock & service levels
- Replenishment optimisation
Poor inventory management drains capital, wastes space, and increases operating costs. Our warehouse consultants deliver effective inventory policies that optimise space and cash flow.
Warehouse management
- Operational process improvement
- Productivity & performance
- Continuous improvement programmes
Efficient warehouses rely on process-driven management to reduce waste and boost productivity. Leveraging proven methods like Kaizen, Six Sigma, and TQM, our consultants can optimise every aspect of your operations.
Warehouse location analysis
- Network modelling
- Site location assessment
- Transport cost optimisation
Warehouse location is critical to cutting transport costs and speeding up delivery. Our consultants use advanced modelling to pinpoint the optimal number and placement of distribution sites for maximum efficiency.
Warehouse facility search
- Property search & selection
- Site evaluation & due diligence
- Lease & acquisition support
Finding the right warehouse takes time. Our consultants manage the entire process – from blueprint design and location selection to facility search and conveyancing – so you can focus on running your business.
Warehouse automation
- Business case & feasibility
- Automation concept & solution design
- Provider selection & implementation
INSIGHT
Warehouse articles & advice
Our warehouse consultants regularly publish practical advice on warehouse design, warehouse optimisation, inventory management and operational improvement. The articles below provide guidance on improving warehouse efficiency and reducing operating costs.
Effective Warehouse Design – The 5 Step Approach
Warehouses are typically designed around the primary functions of receiving, storage, retrieval, and despatch. The objective of effective warehouse design is to ensure each function
A New and Disruptive Model of Warehousing is on its Way
The UK start-up, Stowga, is in the process of bringing a disruptive model to the way warehousing has been previously managed, akin to that of
What to Consider Before Extending a Warehouse Lease
As businesses evolve, customer order patterns change and customer territories expand, it’s not unusual for the distribution requirements of a business to change significantly. Over