Colorado Warehouse Projects: Real Case Studies & Results
See quantified results from 5 recent Colorado warehouse projects across aerospace, food distribution, automotive, electronics, and brewing industries. Projects span Denver metro, Boulder County, Colorado Springs, and Fort Collins with proven ROI and measurable improvements.
Denver Aerospace Manufacturing Facility Expansion
Aurora, Colorado • Aerospace Manufacturing
Project Impact
Project Overview
Complete redesign of 180,000 sq ft aerospace parts warehouse to accommodate increased production demands while maintaining strict quality and security requirements. Project included installation of 35-foot high selective pallet racking with specialized anti-static features for sensitive electronic components.
Challenge
Client needed to triple storage capacity within existing facility footprint while maintaining aerospace industry compliance (AS9100) and implementing automated inventory tracking. Previous racking system couldn't support the weight requirements for titanium alloy storage.
Solution
Designed and installed heavy-duty structural steel racking system with 8,000 lb beam capacity, integrated RFID tracking compatibility, and specialized grounding systems for ESD protection. Implemented narrow-aisle configuration with wire guidance to maximize density.
Project Specifications
Equipment Used
- 450 frames of 42' H x 48' W structural uprights
- 1,200 pairs of 8,000 lb capacity W6x15 beams
- Anti-static wire decking with grounding strips
- Column guards and end-of-aisle protection
- LED bay lighting integrated with rack structure
Quantified Results
"PRLwarehouse delivered exactly what we needed - a system that could handle our specialized requirements while dramatically increasing our storage capacity. The project was completed on time and the quality exceeded our expectations."
Boulder County Food Distribution Center
Longmont, Colorado • Food Distribution
Project Impact
Project Overview
Complete retrofitting of 95,000 sq ft refrigerated warehouse to accommodate growing regional food distribution needs. Project focused on maximizing storage density while maintaining proper air circulation and temperature control in freezer (-10°F) and cooler (34°F) environments.
Challenge
Existing drive-in racking was inefficient and created temperature inconsistencies. Client needed FIFO rotation capability for perishable goods and better accessibility for order picking while working within the constraints of an existing refrigerated building.
Solution
Replaced drive-in system with selective pallet racking optimized for cold storage. Implemented specialized galvanized finish to prevent corrosion, integrated with existing sprinkler and air circulation systems, and designed aisles for reach truck operation in confined spaces.
Project Specifications
Equipment Used
- 285 frames of 28' H selective pallet racking
- 720 pairs of 3,200 lb capacity teardrop beams
- Galvanized finish for corrosion resistance
- Specialized low-temperature wire decking
- Integrated conveyor support structures
Quantified Results
"The new racking system transformed our operation. We can store 74% more product in the same space and our energy bills dropped significantly due to better air circulation."
Denver Automotive Parts Consolidation
Commerce City, Colorado • Automotive Distribution
Project Impact
Project Overview
Consolidation of three separate automotive parts warehouses into single 125,000 sq ft facility using advanced multi-level racking system. Project enabled client to reduce real estate costs while improving inventory access and order fulfillment speed for 15,000+ automotive SKUs.
Challenge
Client was operating from three leased facilities across Denver metro area, creating inefficiencies in inventory management and fulfillment. Needed to consolidate operations while maintaining rapid access to fast-moving parts and accommodating parts ranging from small clips to engine blocks.
Solution
Designed hybrid storage system combining selective racking for fast movers, drive-in racking for bulk items, and multi-tier shelving for small parts. Integrated pick modules with conveyor systems and implemented zone-based organization by vehicle make/model.
Project Specifications
Equipment Used
- 380 frames of variable height selective racking (16'-32')
- 950 pairs of mixed capacity beams (2,500-6,000 lbs)
- Multi-tier pick modules with integrated stairs
- 125 sections of drive-in racking for bulk storage
- Comprehensive safety equipment and lighting
Quantified Results
"PRLwarehouse helped us achieve what seemed impossible - consolidating three warehouses while actually improving our service levels. The ROI was incredible."
Colorado Springs Electronics Manufacturing
Colorado Springs, Colorado • Electronics Manufacturing
Project Impact
Project Overview
Installation of specialized clean room compatible storage system for electronics manufacturing facility producing military-grade components. Project required adherence to ISO 14644 Class 1000 clean room standards while maximizing storage density for sensitive electronic components.
Challenge
Facility needed to expand component storage within existing clean room environment without compromising air quality or contamination control. Previous shelving was inadequate for growing production demands and didn't meet updated military contract requirements for organization and traceability.
Solution
Designed and installed electropolished stainless steel racking system with integrated anti-static features and HEPA-compatible design. Implemented bin-level identification system and created contamination-free access paths for material handling equipment.
Project Specifications
Equipment Used
- 145 sections of electropolished stainless steel racking
- 480 anti-static component bins with clear lids
- Clean room compatible leveling feet
- Integrated label holders for component identification
- ESD-safe accessories and grounding systems
Quantified Results
"The attention to clean room requirements was exceptional. We maintained our ISO certification throughout installation and the new system has significantly improved our production efficiency."
Fort Collins Craft Brewery Expansion
Fort Collins, Colorado • Beverage Manufacturing
Project Impact
Project Overview
Custom barrel aging storage solution for rapidly growing craft brewery needing to expand barrel-aged beer production. Project included specialized racking for 55-gallon bourbon barrels and temperature-controlled packaging storage for finished products.
Challenge
Brewery was paying premium rates for off-site barrel storage and needed in-house solution that could accommodate barrel aging requirements including easy access for sampling, rotation, and cleaning. Space constraints required vertical storage while maintaining safe access for brewery workers.
Solution
Engineered custom barrel racking system with integrated safety features, specialized cradles for barrel stability, and accessible sampling points. Included separate climate-controlled area for packaging storage with easy forklift access and first-in-first-out flow.
Project Specifications
Equipment Used
- Custom barrel cradle racking for 2,100 positions
- Reinforced 20' high structural steel framework
- Integrated safety railings and access platforms
- 180 positions of case goods storage racking
- Climate monitoring integration points
Quantified Results
"This system paid for itself in 5 months just from eliminating off-site storage costs. The custom barrel racking is exactly what we needed to scale our barrel-aged program."
Project Summary by Industry
Manufacturing Projects
Distribution Projects
Specialty Projects
Geographic Coverage
Projects completed across Colorado Front Range: Denver Metro (Aurora, Commerce City), Boulder County (Longmont), Colorado Springs, and Fort Collins. Combined facility size: 443,000 square feet.
Key Project Insights
Storage Optimization Results
- Average storage increase: 98.8% across all projects
- Highest gain: 147% storage increase (Fort Collins brewery)
- Operational efficiency improved 57.6% on average
- Combined annual savings: $301,000 across all projects
Implementation Success Factors
- Average project duration: 5.2 weeks
- 100% on-time or early completion rate
- Industry compliance maintained (AS9100, ISO 14644)
- Average ROI achieved in 11.4 months
Frequently Asked Questions
What are typical results from warehouse storage optimization in Colorado?
Based on our 5 recent Colorado projects, clients see an average 98.8% storage capacity increase, $301,000 in annual savings, and ROI in 11.4 months. Projects range from aerospace manufacturing in Aurora to food distribution in Longmont, with storage improvements from 73% to 147% depending on existing layout and requirements.
How long do warehouse racking projects take to complete in Colorado?
Colorado warehouse projects typically take 3-8 weeks depending on complexity. Our Fort Collins brewery project took 3 weeks, while the Denver automotive consolidation required 8 weeks. Average project duration is 5.2 weeks including engineering, permitting, and installation phases.
What industries have you worked with for warehouse storage in Colorado?
We've completed projects across aerospace manufacturing (Aurora), food distribution (Longmont), automotive parts (Commerce City), electronics manufacturing (Colorado Springs), and craft brewing (Fort Collins). Each industry has specialized requirements we accommodate, from clean room compliance to cold storage optimization.
What is the typical ROI for warehouse storage improvements in Colorado?
Our Colorado projects show ROI ranging from 5-18 months, averaging 11.4 months. The Fort Collins brewery saw 5-month ROI through eliminated off-site storage costs, while the Denver aerospace project achieved 18-month ROI through operational efficiency gains and reduced labor costs.
Can you handle specialized storage requirements in Colorado warehouses?
Yes, we specialize in complex requirements: anti-static racking for aerospace components, galvanized systems for cold storage, clean room compatible stainless steel, and custom barrel storage solutions. Each Colorado project is engineered for specific operational and compliance requirements.
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