Getting the number of stillages right matters more than most warehouse managers realise. Too few and you create bottlenecks that slow operations; too many and you waste valuable floor space and capital. With over 40 years of experience manufacturing stillages for UK warehouses, we’ve helped countless operations determine their exact requirements.
Here’s our practical method for calculating how many stillages your operation needs, covering inventory assessment, space planning, and future-proofing your investment.
What Are Your Current Storage Requirements?
Before any calculation, you need a clear picture of what you’re actually storing. This means documenting the volume, dimensions, and weight of the goods that will sit in each stillage.
Audit Your Inventory
Review your current stock levels and categorise items by size and type. Goods that are irregularly shaped or cannot be palletised conventionally are prime candidates for stillage storage. Record the average quantity held at any one time—this baseline figure drives the rest of your calculation.
Account for Turnover Rate
A warehouse with rapid stock turnover may need fewer stillages than one holding slow-moving inventory. If goods ship out within days, each stillage is freed up quickly and can be reused. Slower-moving lines tie up stillages for longer, meaning you need more units to maintain the same operational flow.
How Do You Calculate the Number You Actually Need?
Once you know your inventory profile, the core formula is straightforward:
Number of stillages = Total volume of goods ÷ Usable volume per stillage
Start by calculating the usable internal dimensions of the stillage (length × width × height), then factor in a clearance allowance of around 50 to 100 mm per side for safe loading and unloading. Divide your total goods volume by this figure to arrive at a base number.
Factor in Stacking Height
Stillages that stack multiply your storage capacity vertically. If your warehouse ceiling height allows three-high stacking and your stillages are rated for it, three stacked units occupy the same footprint as one. This dramatically reduces the total number of stillages needed to cover your floor area, though you must confirm that your forklift’s lifting height can reach the top tier safely.
Our steel stillages are built to withstand the rigours of stacking – using steel with the structural integrity to handle heavy loads without buckling over time.
Build in a Buffer
Industry practice typically suggests adding 10 to 15 percent to your calculated total. This buffer covers seasonal demand peaks, new product lines, and stillages temporarily out of circulation for maintenance or transit. It’s a practical safeguard that prevents you from running short during busy periods.
What About Future Growth?
Historical stock data is useful, but forecasting is equally important. If your business is expanding or diversifying its product range, factor projected growth into your figures now. Purchasing additional stillages reactively often costs more and causes short-term disruption compared with planning ahead.
We regularly work with businesses to create scalable stillage solutions—designing units that can adapt as requirements change rather than becoming obsolete as operations evolve.
Don’t Overlook Your Facility Layout
Walk your warehouse floor and measure available storage zones, aisle widths, and access points. Wider aisles are needed where forklifts operate, and fire safety regulations require clear escape routes. The physical space you can dedicate to stillage storage sets an upper limit regardless of what your inventory calculations suggest.
Consider how stillages will move through your facility. Tight corners, loading bay clearances, and turning circles all affect whether your chosen dimensions will work in practice.
Why Choose Range Storage for Your Stillages?
Since 1979, we’ve manufactured over 500,000 stillages for warehouses, manufacturers, and distribution centres across the UK. As a family business based in West Yorkshire, we understand that getting your stillage requirements right isn’t just about numbers – it’s about creating solutions that work in real-world conditions.
Every stillage we produce is manufactured in-house at our Dewsbury facility. UK. This complete control over the manufacturing process means we can deliver:
- Bespoke solutions tailored to your exact dimensions and load requirements
- Quality you can rely on—our ISO 9001 accreditation backs up our commitment to durability
- Expert consultation to help you calculate the right quantity and specification
- Fast turnaround times from our 25,000 sq ft factory
- Competitive pricing without compromising on quality
Whether you need a handful of units or a full warehouse fleet, we’ll work with you to match your calculations to the right product specification.
Get Your Stillage Solution Right
Not sure where to start with your calculations? Contact our team today — we’ll help you assess your requirements and recommend stillage solutions that deliver long-term value. With four decades of manufacturing experience, we’ve seen every warehouse configuration and can spot potential issues before they become problems.
Request a free, no-obligation quote today, and let’s discuss how our British-made stillages can improve your warehouse operations.
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