Why small parts storage is a different problem
Pallet storage is optimised around load capacity and floor space per pallet; small parts storage is optimised around pick frequency, SKU density, and how quickly a person can find and retrieve one item among hundreds. Applying pallet-storage thinking, bigger is better, fewer touches is better, to small parts picking usually gets the answer wrong.
Bins vs totes: what’s actually different
Bins are typically fixed or semi-fixed containers used to divide shelf space into pick locations, while totes are moveable containers that travel with the stock, between receiving, storage, and packing. Choosing between them comes down to whether the container needs to stay in place as a pick location or move through the process with the goods inside it.
Matching container size to pick frequency
Fast-moving SKUs picked constantly need small, easily-handled containers positioned at accessible heights, while slower-moving stock can sit in larger containers further from the primary pick face. Sizing every container the same regardless of how often it’s picked is a common way warehouses lose picking speed without realising why.
Shelving that supports small parts properly
Shortspan shelving, a heavy-duty boltless system with closer upright spacing, is built specifically for this kind of dense, hand-picked storage, and pairs naturally with a well-sized bin and tote layout on top of it. Standard pallet racking bays, by contrast, waste height and access speed when used for small parts they were never designed to hold. See our full breakdown of Widespan, Shortspan and Cantilever Shelving for how shortspan compares to the other bulk shelving types.
Labelling and location systems
A bin or tote system only works as fast as staff can find the right one, which means clear, consistent location labelling, whether that’s simple shelf-edge labels or a full location-coding system, matters as much as the containers themselves. This is often the cheapest fix available for a picking area that feels slow, and the one most commonly skipped.
Getting density and speed to work together
The temptation in small parts storage is to maximise density, cramming in as many SKUs as possible, but density that slows picking down defeats the purpose. The better goal is the highest density that still keeps your fastest-moving lines quick to reach, which usually means a deliberate mix of container sizes rather than one standard size throughout.
And finally…
Small parts storage rewards a different kind of planning than pallet storage, one built around pick frequency and container fit rather than raw capacity. Getting bins, totes and shelving matched to how stock actually moves is what turns a cramped picking area into a fast one.
If your small parts picking area feels slower than it should, Rackline can help you work out where the container and shelving mix is costing you time. Call 01782 770144, email info@rackline.co.uk, or fill in the form below and one of the team will be in touch.