Warehouse Organisation: Best Practices for Storage Container Systems

The Short Answer

Good warehouse organisation comes down to three principles:

1. Zone your warehouse – different areas need different storage solutions.
2. Match containers to tasks – picking needs different boxes than bulk storage.
3. Optimise vertical space – but only where it makes operational sense.

Get these right and you'll reduce picking times, eliminate searching for stock, and maximise every square metre of your facility.

Different Zones, Different Storage

Not all warehouse space is the same. Each zone has different functions — and different storage needs. Matching the right containers to each area is the foundation of efficiency.

Picking Zone

Purpose: Fast access to frequently picked items.
Needs: Quick access, clear visibility, easy retrieval.

Best containers:

• ✅ Open-front euro containers (Pickmaster style)
• ✅ Small–medium euro containers on shelving
• ✅ Picking bins with label holders
• ✅ Clear containers for visibility

Why it works: Speed is everything. Removing lids or hunting through boxes adds up to hours lost each week. Open-front and clear containers reduce picking time by 3–5 seconds per item — hundreds of hours a year in busy facilities.

→ View Pickmaster Open-Front Containers 

Bulk Storage Zone

Purpose: Long-term or infrequently accessed stock.
Needs: Capacity, stackability, dust protection.

Best containers:

• ✅ Large euro containers (60L–90L+) on pallet racking
• ✅ Attached lid containers for dust-free storage
• ✅ Pallet boxes for bulky items
• ✅ Solid containers with separate lids

Why it works: Bulk storage prioritises protection over access. Large, stackable euro containers maximise vertical space while keeping stock clean and stable.

Work-in-Progress (WIP) Zone

Purpose: Items being assembled, processed, or kitted.
Needs: Mobility, frequent access, clear visual organisation.

Best containers:

• ✅ Medium euro containers (20L–45L)
• ✅ Containers on dollies for movement
• ✅ Colour-coded containers by stage or product
• ✅ Stackable containers that separate easily

Why it works: Containers move with the workflow. Using dollies and colour-coding keeps production flowing smoothly.

Dispatch & Loading Zone

Purpose: Orders ready to ship.
Needs: Security, dust protection, efficient return.

Best containers:

• ✅ Attached lid containers (tamper-evident, nest when empty)
• ✅ Euro containers for pallet loads
• ✅ Sealable containers for secure transit

Returns Processing

Purpose: Sorting returned items.
Needs: Separation, clarity, temporary holding.

Best containers:

• ✅ Colour-coded attached lid containers
• ✅ Clear euro containers for inspection
• ✅ Medium containers for sorting batches

Why it works: Visual separation prevents re-stocking errors and keeps workflows tidy.

Stack Smart, Not Just High

Vertical space is valuable — but only when it doesn’t slow operations or create risks.

Stack high:
✅ Bulk storage zones
✅ Reserve or seasonal stock
✅ Archive materials

Keep low and accessible:
❌ Picking zones
❌ WIP areas
❌ Frequently accessed parts

Stacking guidelines:

• Small boxes (10–20L): 8–10 high
• Medium boxes (40–60L): 5–6 high
• Large boxes (80L+): 3–4 high
• Always use matching sizes and respect weight limits

Pro tip: Euro containers interlock via their rim for stable stacking — up to 10 high when properly loaded.

Why Euro Sizes Matter

Euro footprints (200×150, 300×200, 400×300, 600×400, 800×600 mm) fit exactly on standard pallets.

Why it matters:

• Full pallet utilisation = zero wasted space
• Faster loading/unloading
• Easier inventory counting
• Lower transport costs

Example: Using 400×300 mm boxes allow 8 SKUs per pallet — 100% space used, 0% wasted.

Read our Size Guide

FIFO, FEFO, and Container Choice

Stock rotation isn’t just for food — it applies to everything with a shelf life or version control.

FIFO (First In, First Out)

• Label containers with receipt dates
• Store front-to-back on shelving
• Use colour-coded lids by week

FEFO (First Expired, First Out)

• Clear containers for visibility
• Large date labels on each container
• Colour-coded zones (green = fresh, red = urgent)

Pro tip: One batch per container only — prevents hidden old stock.
→ View Label Holders

Small Details, Big Differences

Ventilation

Use ventilated or perforated containers for:

• Produce and chilled goods
• Moisture-sensitive items
• Condensation-prone environments

→ View Ventilated Containers

Clear vs Solid

• Clear: Fast identification, great for picking.
• Solid: Better for appearance, light protection, outdoor use.
  Most warehouses use both — clear for picking zones, solid for storage.

Attached vs Separate Lids

• Attached: Tamper-evident, secure, nestable.
• Separate: Faster access, lower cost, but can get lost.
  → Read: Attached Lid vs Euro Containers

Colour-Coding

Use colours for product type, priority, or status:
🟩 Standard 🟥 Urgent 🟦 Returns 🟨 Damaged
A consistent colour system reduces confusion and speeds decisions.

Common Warehouse Mistakes

• ❌ Using random container sizes → wastes space
  ✅ Fix: Standardise on euro footprints.
• ❌ Over-packing boxes → cracks and injuries
  ✅ Fix: 80–90% fill rule.
• ❌ Inconsistent labelling → lost time, errors
  ✅ Fix: Label everything, same place, same format.
• ❌ Prioritising space over access → slower picks
  ✅ Fix: Keep fast-movers accessible.
• ❌ Using cardboard in storage areas
  ✅ Fix: Replace with plastic containers — cleaner, stronger, reusable.
  → [See Cardboard vs Plastic ›]

Measuring Your Results

Track before and after reorganisation:

Speed:

• Picking time per order
• Time to locate an SKU

Accuracy:

• Picking error rate
• Stock count accuracy

Space:

• Items stored per m²
• Pallet positions utilised

Target improvements:

• 20–30% faster picking
• 50% fewer errors
• 15–25% more storage capacity

Your Action Plan

Week 1 – Audit & Plan

• Map zones, note bottlenecks, count containers.

Week 2 – Choose Containers

• Match sizes and features to each zone.

Week 3 – Implement One Zone

• Start with picking area. Train staff. Label everything.

Week 4 – Refine & Expand

• Review results, adjust, repeat zone by zone.

Pro tip: Don’t reorganise everything at once. Learn as you go.

The Verdict

Great warehouse organisation isn’t about buying more storage — it’s about using the right containers in the right places.

Key principles:

1. Zone by function
2. Match container type to task
3. Standardise on euro sizes

The payoff: faster picking, fewer errors, better space use, and smoother operations.