How Mezzanines Can Improve 3PL Order Fulfillment in E-Commerce Warehouses

As the world of e-commerce continues to grow and evolve, so do the demands placed on 3PL (third-party logistics) providers and their warehouse and distribution operations. With consumers expecting faster shipping times and more flexible delivery options than ever before, the pressure is on for 3PLs to optimize their online order fulfillment processes and increase efficiency wherever possible.

One solution that has proven effective for many 3PLs is the use of structural mezzanines within their warehouse facilities. Mezzanines are elevated platforms that can be installed within an existing warehouse space to increase usable square footage, which can lead to increased productivity and improved safety. 

In this article, we'll explore the benefits of using mezzanines for 3PLs, mezzanine design considerations, a success story of a Fortune 50 3PL provider, and cost considerations for those considering a mezzanine system.

Benefits of Structural Mezzanines for 3PL Providers

One of the biggest challenges facing 3PL providers today is the need for additional warehouse space to accommodate growing inventory and order volume. However, expanding into new facilities or leasing additional space can be expensive and time-consuming, particularly in high-demand urban areas. This is where mezzanine systems come into the picture.

Mezzanines are essentially raised platforms that create additional floor space within an existing warehouse or distribution center. By going up rather than out, 3PL providers can effectively double or triple their available square footage without the need for costly and disruptive building expansions. This makes mezzanines an ideal solution for 3PLs looking to optimize their use of existing space and maximize their return on investment.

Another key benefit of mezzanines is their ability to increase productivity within a warehouse or distribution center. By providing additional floor space, mezzanines can facilitate the creation of more efficient layouts and workflows, reducing the need for workers to traverse long distances within the facility. This can help to reduce overall processing times and increase order throughput, improving overall productivity and profitability.

Mezzanines can also enhance safety within a warehouse or distribution center. By providing additional space for storage, processing, and packing, mezzanines can help to reduce congestion on the ground floor, minimizing the risk of accidents or injuries. Additionally, many mezzanines are designed with features such as guardrails, staircases, and safety gates that are OSHA-compliant and designed to prevent falls and further enhance worker safety.

Mezzanine Design Considerations for 3PL

When designing a mezzanine for a 3PL warehouse, there are several considerations to keep in mind. One of the most important is height and clearance restrictions. The height and clearance of the mezzanine must be designed to comply with local building codes and regulations. Additionally, the load capacity of the mezzanine must be determined based on the weight of the products being stored and any equipment that will be used on the mezzanine.

Access points are also an important consideration. Mezzanines should be designed with sufficient access points to allow for the efficient movement of products and equipment. This may include stairs, elevators, or lifts. Mezzanine design should also take into account the layout of the warehouse and the location of existing infrastructure such as fire sprinklers and lighting systems.

Several e-commerce areas may benefit from mezzanine systems.

Returns

Returns management is a crucial aspect of any 3PL operation, as it can significantly impact customer satisfaction and ultimately affect the bottom line. It is a time-consuming and complex process, often involving multiple steps and parties. This is particularly true for e-commerce businesses, where the volume of returns can be high.

To address this challenge, many 3PLs are turning to mezzanines to create dedicated returns areas that can streamline the process and increase efficiency. By having a separate space on a mezzanine level, 3PLs can better manage the flow of returned goods and reduce the risk of errors or delays. This can ultimately lead to faster processing times and improved customer service.

In addition, a dedicated returns area on a mezzanine level can also free up valuable floor space on the main level of the warehouse. This can be especially beneficial for warehouses that are already crowded or have limited space to work with.

Pick and Pack 

In many fulfillment warehouses, the pick-and-pack area is the heart of the operation, where employees move around the floor to collect items and get ready to ship orders. However, this traditional approach can limit space utilization and the number of pick-and-pack stations available. 

By taking a multi-level approach to this critical area, 3PLs can maximize the use of available space without sacrificing valuable square footage on the warehouse floor. One way to achieve this is by installing a mezzanine level with dedicated pick-and-pack stations. 

This approach offers several advantages, including increased efficiency, higher productivity, and more streamlined operations. This is a great option for 3PLs to ensure they’re making the most of their available space while also improving their ability to meet customer demands. Furthermore, this approach allows for more flexibility and scalability as demand grows, without the need to expand the warehouse footprint.

Additional Shelving/Pick Locations

As a business expands its operations, it may face the challenge of finding adequate space for storing inventory and managing its products. This challenge is especially pronounced for 3PLs, who need to find ways to increase their number of pick locations.

Mezzanine floors are a great e-commerce storage solution, as they can provide additional space for shelving and pick locations without requiring additional square footage on the warehouse floor. By utilizing the vertical space available in their facility, 3PLs can increase their storage capacity and improve their operational efficiency.

Implementing a mezzanine system can also provide other benefits beyond increased storage capacity. For example, it can create a more organized and streamlined workflow by consolidating similar products in one area, reducing the time and effort required for picking and packing. Additionally, mezzanine systems can help to optimize space utilization, enabling 3PLs to allocate more space for higher-value products or to accommodate seasonal inventory fluctuations.

In all of these scenarios, a mezzanine system can help a 3PL optimize its use of space, increase productivity, and improve efficiency. By expanding vertically in their warehouse, 3PLs can avoid the need for costly expansion or relocation, and make the most of their existing space. 

3PL Provider Increases Pick Locations with a Mezzanine System

A Fortune 50 E-commerce 3PL provider wanted to increase the number of pick locations. Their dilemma? Deciding between moving into a new facility or building a multi-level mezzanine in their existing warehouse. 

Within two days of contacting Mezzanine Distributors, we provided them with a firm budget price. With estimated savings of about $1.5 million, they opted for a mezzanine system, which allowed them to add two additional levels of pick locations quickly and economically.

The mezzanine system was designed with safety features such as guardrails and gates to prevent falls, as well as stairs and a lift to provide access to the mezzanine. The mezzanine system also included NFPA-compliant fire sprinklers and LED lighting systems to comply with local building codes and improve safety.

"Mezzanine Distributors was a great partner with our expansion project. Ahead of schedule and under budget, along with timely communications and project management resulted in a very successful experience. We will definitely go to Mezzanine Distributors again for future expansions. Thank you Pearce Farnum for going the extra mile. Great job!"

Cost Considerations of Structural Mezzanines for 3PL Providers

When it comes to cost considerations, there are several factors to keep in mind. Still, as we just witnessed with our Fortune 50 E-commerce 3PL provider, the cost savings associated with mezzanines are significant.

For mezzanine systems of any considerable size (i.e. over 3,000 SF), full, turnkey mezzanine systems (full design-build mezzanine services including fire sprinkler and LED lighting systems) can achieve usable square footage at 35-50% savings when compared to building or purchasing a new facility. 

Opting for a turnkey mezzanine solution can also provide long-term cost savings compared to leasing a facility. While leasing can provide short-term flexibility, it ultimately leads to increasing monthly operational costs that come with the space, including utilities, taxes, additional labor, and additional operational complexities, such as material and transportation management. In contrast, making a one-time investment in a mezzanine system can provide a permanent asset that can be used for years to come, without the need for ongoing lease payments.

Shelving Supported Mezzanines

While structural mezzanines may be the go-to option for larger spaces, there are certain scenarios where a shelving-supported mezzanine can be a better choice. These types of mezzanines utilize a shelving system to support the second level, providing additional storage or workspace without the need for a full structural mezzanine. 

One of the key benefits of using shelving-supported mezzanines is that they can be installed quickly and easily. Compared to a full structural mezzanine with standalone shelving, they are often a more cost-effective option as you do not need structural columns in addition to the shelving units.

Additionally, shelving-supported mezzanines can be customized to fit specific requirements, allowing 3PLs to tailor their solutions to their unique needs.

Conclusion

In conclusion, structural mezzanines can be a game-changer for 3PL order fulfillment in e-commerce warehouses. With their ability to increase space utilization, enhance safety, and boost productivity, they offer significant benefits that can help companies meet the challenges of the modern warehousing and distribution industry.

At Mezzanine Distributors, we specialize in providing high-quality mezzanine solutions for businesses of all sizes. With our expertise in mezzanine design, engineering, and installation, we can help you maximize your space and optimize your operations.

If you're interested in learning more about how mezzanines can benefit your business, please don't hesitate to contact us.