Zowell Narrow-Aisle Solution Enhances Pallet Handling and Order Picking for European Hardware Customer

One Aisle, One Dedicated Truck: Zowell Narrow-Aisle Solution Enhances Pallet Handling and Order Picking for European Hardware Customer

Recently, Zowell successfully completed the delivery of four narrow-aisle forklifts to a hardware products distributor and warehouse operator in Europe. The solution includes two man-up VNA forklifts and two high-level order picking trucks.

By adopting a dedicated equipment strategy for different warehouse areas, the customer can now operate full-pallet handling and piece-picking tasks in separate zones, reducing operational interference and improving overall warehouse efficiency.

This project represents another successful Zowell application in the European hardware industry and provides a practical solution for warehouses handling multiple SKUs and different material-handling requirements.

Project Background

The customer is a European distributor and warehouse operator specializing in hardware products, with a large number of SKUs.

The warehouse needs to handle both:

• High-volume full-pallet inbound and outbound operations
• Frequent piece picking and replenishment for individual orders

The customer already had man-up VNA and order picking equipment in operation. However, pallet handling and picking activities were still competing for the same aisles, limiting overall efficiency.

The key requirement was clear: dedicated working zones, independent aisle operations, and higher productivity.

Key Challenges

1. Conflicts Between Pallet Handling and Order Picking

With a wide variety of hardware products and different order profiles, full-pallet storage and retrieval and piece-picking operations previously took place in shared aisles.

Forklift waiting, operator interaction, and the need to avoid other workers could lead to aisle congestion and unnecessary waiting time, affecting overall warehouse productivity.

2. High-Frequency, Labor-Intensive Picking

Hardware orders are typically characterized by many product types, small quantities per SKU, and high picking frequency.

As e-commerce and retail orders continue to increase, the customer needed a more efficient way to support high-frequency picking while improving operator comfort and productivity.

Zowell's Solution

To address the customer's requirements, Zowell provided a solution consisting of:

• 2 × Man-up VNA forklifts
• 2 × High-level order picking trucks

The warehouse's seven aisles were divided into two dedicated operating zones:

• 3 aisles for full-pallet storage and retrieval
• 4 aisles dedicated to piece picking

The four Zowell trucks operate independently within their designated aisles, together with three existing forklifts from other brands in the remaining aisles. This allows different operations to run simultaneously with less interference

Full-Pallet Storage: Man-Up VNA Forklifts

The full-pallet storage area consists of three aisles, two of which are operated by Zowell man-up VNA forklifts.

The standard Zowell man-up VNA model offers:

• Maximum lifting height: up to 18 m
• Rated capacity: up to 1.6 tons

During operation, the operator platform rises together with the forks, providing a clear view of the load and storage location at height. This helps operators achieve more accurate positioning during high-level pallet storage and retrieval.

The trucks are also equipped with an electric three-way fork head, which can rotate 180° in less than 10 seconds, supporting efficient and precise pallet handling in narrow aisles.

High-Frequency Picking: High-Level Order Picking Trucks

The remaining four aisles are dedicated to piece-picking operations, with two Zowell high-level order picking trucks assigned to this area.

For this project, the two picking trucks are equipped with dual-direction driving, allowing operators to drive in either direction without repeatedly repositioning the truck.

The operator platform can be raised directly to the required picking level, enabling a “man-to-goods” picking operation.

This configuration is particularly suitable for hardware warehouses where orders involve many SKUs, small quantities, and frequent picking activities.

By bringing the operator directly to the required storage location, the solution helps improve picking efficiency while also providing a more comfortable working environment for operators.

Key Benefits

01. Productivity Value — One Aisle, One Dedicated Truck

Each aisle is assigned to a dedicated type of operation and equipment, allowing pallet handling and piece picking to run in parallel with less interference.

02. Space Value — Narrow Aisles, Higher Storage Density

The combination of narrow-aisle operation and high-level racking makes better use of available warehouse space and helps increase storage capacity without expanding the facility.

03. Management Value — Clearer Warehouse Operations

Dedicated operating zones make material flow and equipment allocation clearer, helping create a more organized and efficient warehouse management system.

A Practical Solution for Multi-SKU Warehouses

This project demonstrates how dedicated equipment and clear aisle zoning can help warehouses manage different operational requirements more efficiently.

For hardware distributors and other businesses handling large SKU volumes, full-pallet storage, frequent replenishment, and piece picking, Zowell's narrow-aisle equipment provides flexible solutions designed around the actual workflow of the warehouse.

One aisle, one dedicated truck — less interference, better space utilization, and more efficient warehouse operations.