Since 1976, Hystat Systems has been a dependable manufacturer of hydraulic cylinders and accumulators, serving heavy-duty engineering projects globally. As the business expanded, so did the demands on their warehouse facilities and the need for safe storage of thousands of small parts and components. Once space became increasingly restricted, stock control also quickly became congested and time-consuming.
Prodek was given the task of increasing storage capacity while also factoring in and supporting the company’s future growth, reflecting the high-quality products that Hystat is well known for and ensuring they always maintain exceptional standards.
Smarter Storage Without Expansion
Hystat’s initial plan was to install a mezzanine floor to create additional storage space. However, upon a detailed site survey and assessment by Prodek, our team suggested that a bespoke multi-tier shelving system would provide a more practical and cost-effective solution.
Rather than create a single additional level, the new storage system utilised the building’s vertical height by introducing two levels of shelving, fully integrated with pedestrian walkways. This allowed for storage capacity to be increased significantly, while still ensuring each product was fully accessible.
The new system was designed entirely around Hystat’s inventory and workflow, with the installation creating dedicated storage locations for thousands of individual components, transforming previously underutilised vertical space into a highly efficient picking and storage area.
Improving Warehouse Efficiency
The completed installation has dramatically improved warehouse organisation and day-to-day operations. With clearly defined storage locations across two levels, staff can now locate products faster, reducing picking times and improving stock accuracy.
By removing excess stock from the floor level, the warehouse has become safer, cleaner and easier to navigate. Improved walkways and organised shelving have reduced clutter while allowing Hystat to increase inventory capacity without sacrificing valuable operational space.
By eliminating the desire for a mezzanine floor, it demonstrated how the right storage system can often provide greater operational benefits and still fall within set budgets. As part of the project, Prodek also took care of the Building Regulations approval process, providing structural calculations and supporting technical documentation to ensure the installation is compliant and meets all relevant requirements.
A Storage Solution Built for Future Growth
The new multi-tier system has provided Hystat with a scalable storage solution that supports both current operations and future expansion goals. By maximising the building’s existing footprint, rather than extending or relocating, the company has benefitted from increased productivity and greater production.
The work completed by Prodek includes:
- Bespoke multi-tier shelving system design and installation
- Integrated pedestrian walkways
- 69 heavy-duty shelving bays across the ground and first floor
- Shelving with up to seven storage levels per bay
- 200kg total load capacity per shelving bay
- Ribbed steel-deck access walkways
- Industrial integrated access staircase
- Hand, knee and kick rail edge protection
- Mesh cladding to external racking elevations
- Structural calculations
- Building Regulations support
- Pre-galvanised steel finish for long-term durability
Client Testimonial
James Lee, Supervisor at Hystat, was facing a common warehouse challenge: limited space, poor efficiency, and slow picking speeds caused by difficulty locating items. Determined to find a solution, James reached out to Ben at Prodek, who arranged a site visit to assess the space firsthand.
Initially, Hystat had been considering a mezzanine floor. But after discussing the layout with Ben, it became clear that a racking system would deliver far greater benefit. To see the concept in action, the Prodek team arranged a visit to another customer site using a similar racking solution, leaving James and the team impressed and confident in the direction.
From there, Prodek managed the entire project, including all building regulations, with excellent communication throughout. The installation itself took just three to four days, and the results speak for themselves.
“Working with Prodek has been excellent from start to finish. The team did a fantastic job, and I’d recommend Prodek to anybody.” — James Lee, Supervisor, Hystat
Project Galley
