Estimated reading time: 8 minutes
Very Narrow Aisle (VNA) pallet racking is one of the most effective warehouse efficiency solutions for logistics companies looking to maximise storage capacity without expanding their physical footprint. In January 2025, we completed a custom VNA industrial pallet racking project for ProTrans, a fast-growing Irish logistics and distribution company. We delivered over 100 tonnes of high-density racking, creating 5,500 pallet locations within a confined warehouse space. This project shows what's possible when you combine strategic warehouse layout design with the right storage system.
Project Overview: ProTrans VNA Racking Installation
| Project Detail | Specification |
|---|---|
| Client | ProTrans |
| Industry | Logistics & Distribution |
| Location | Ireland |
| System Type | Very Narrow Aisle (VNA) Pallet Racking |
| Total Racking Supplied | Over 100 tonnes |
| Pallet Locations Created | 5,500 |
| Completion Date | January 2025 |
| Key Benefits | Maximum pallet capacity, seamless MHE integration, future scalability, minimal operational disruption. |
| Compliance | EN 15635, EU safety regulations |
What Are the Project Requirements for a High-Density VNA Racking System?
The brief from ProTrans was clear: deliver maximum pallet capacity within a limited floor area and maintain operational efficiency. John McGrath and the ProTrans team needed a storage solution that could keep pace with rapidly growing demand. It had to integrate seamlessly with their existing VNA handling equipment without compromising accessibility or workflow safety.
Several factors shaped the project requirements. The system needed to accommodate high-density storage and allow precise forklift navigation through very narrow aisles. Accessibility remained a priority, as warehouse operatives needed efficient picking routes and clear sightlines throughout the facility. The timeline was tight too, with minimal tolerance for operational downtime during the busiest trading period.
From a technical standpoint, the VNA pallet racking system needed to meet stringent EU safety regulations, including compliance with EN 15635 standards for static steel storage systems. The racking design also had to accommodate future growth. ProTrans wanted the flexibility to expand capacity as their business grows without requiring a complete system overhaul.
Our approach prioritised precision in planning from day one. We conducted comprehensive site surveys and load calculations, ensuring every component specification aligned with the facility's structural capabilities and the client's operational workflows.
How Do You Design a Warehouse Layout for VNA Forklifts and Space Optimisation?
When we approached the ProTrans facility, our warehouse layout design process began with a thorough assessment of the site's unique characteristics. The premises offered limited floor space but generous vertical clearance. This presented an ideal opportunity for a VNA warehouse racking configuration that prioritises height over horizontal spread.
So what makes VNA racking systems different from conventional wide aisle alternatives? Traditional warehouse layouts typically require aisle widths of 2.5 to 3.5 metres to accommodate standard counterbalance forklifts. Very narrow aisle racking reduces aisle widths to as little as 1.5 metres, using specialist turret trucks or articulated VNA forklifts that operate within these tighter confines. This approach can increase storage density by 40-50% compared to conventional selective racking arrangements.
For the ProTrans project, our design team engineered a layout that maximised vertical space utilisation and ensured smooth integration with the client's material handling equipment (MHE). We configured the warehouse floor plan to optimise traffic flow, separating inbound and outbound operations to reduce bottlenecks and improve picking efficiency. We also incorporated guide rail systems to ensure precise forklift navigation, reducing the risk of accidental racking strikes and enhancing overall safety.
The design process accounted for future growth too. We built flexibility into the racking configuration, allowing ProTrans to add additional bays without disrupting existing operations. This forward-thinking approach means ProTrans can scale their storage infrastructure in line with business expansion, avoiding costly retrofitting projects down the line.
Watch how we approach large-scale warehouse layout design in our project overview video.
What Is Very Narrow Aisle Pallet Racking and How Does It Maximise Warehouse Efficiency?
Very narrow aisle pallet racking is a high-density storage system specifically designed to maximise warehouse space optimisation by significantly reducing the aisle width required between racking runs. We engineer these systems to work with specialised VNA forklifts, which feature rotating masts or articulated arms capable of operating in confined spaces where standard forklifts can't manoeuvre.
The key advantage of a VNA racking system is its ability to convert previously unusable floor space into productive storage capacity. By reducing aisle widths from the typical 2.5 to 3.5 metres required for conventional racking down to approximately 1.5-1.8 metres, VNA systems allow warehouses to install more racking runs within the same footprint. Combine this with high-bay configurations that extend storage vertically, and you get a dramatic increase in pallet positions without any building extension.
For ProTrans, we supplied and installed a comprehensive VNA pallet racking system comprising over 100 tonnes of heavy-duty steel components. The solution delivered precisely 5,500 pallet locations, each designed to handle the load profiles specified by the client.
We're the sole Irish distributor for Kimer, who bring over 50 years of expertise in designing and manufacturing industrial storage systems.
Our team worked meticulously to ensure every upright, beam and safety component was positioned with millimetre precision. This level of accuracy is essential for VNA operations: even minor misalignments can impede forklift navigation and create safety hazards.
Results: How VNA Racking Transformed ProTrans Operations
The completed system delivered immediate and measurable improvements to ProTrans's warehouse operations. The most significant outcome? A substantial increase in storage capacity, enabling the client to accommodate considerably higher stock volumes without expanding their existing premises. For a growing logistics company operating in a competitive market, this capacity boost provides essential headroom to meet rising customer demand.
Operational efficiency improved noticeably following the system handover. The optimised warehouse layout, with clearly defined traffic routes and streamlined aisle navigation, reduced picking times and minimised forklift travel distances. The guide rail system we installed alongside the racking ensures that VNA forklifts maintain precise alignment, protecting both the equipment and the racking infrastructure from collision damage.
We upheld safety standards throughout the process. All racking components meet EU regulations and EN 15635 requirements, providing ProTrans with documented compliance for health and safety audits. We incorporated upright protectors and other racking accessories where necessary, adding additional safeguards in high-traffic zones.
Perhaps most importantly, we completed the project on schedule with minimal disruption to daily operations. Our team coordinated closely with ProTrans management to phase the work around their busiest periods, ensuring continuity of service for their customers throughout.
This project is a perfect example of how the right racking solution can unlock massive potential in a fast-growing logistics environment. By leveraging a VNA system, we helped the client maximise their vertical space without compromising efficiency or future scalability. It's always rewarding to deliver a system that not only meets immediate operational needs but also sets a strong foundation for long-term growth.
— Ciaran Duffy, Director, RackZone
"Related Warehouse Storage Solutions
Alongside VNA pallet racking, we offer a comprehensive range of complementary storage solutions for logistics and distribution environments:
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Frequently Asked Questions (FAQs)
How can I increase pallet capacity without expanding the warehouse?
VNA (Very Narrow Aisle) racking is the most effective solution for increasing pallet capacity without expanding your warehouse footprint. This system reduces aisle widths to approximately 1.5 metres, allowing more racking runs within the same floor area and maximising vertical storage height.
Is Very Narrow Aisle (VNA) racking worth it for a small footprint warehouse?
VNA racking is particularly worthwhile for small footprint warehouses with sufficient ceiling height. The system converts unused vertical space into productive storage, often increasing capacity by 40-50% compared to conventional racking layouts without requiring building extensions.
What's the difference between VNA and wide aisle racking?
The primary difference is aisle width. Wide aisle racking requires aisles of 2.5 to 3.5 metres for standard forklifts. VNA racking operates with aisles of approximately 1.5-1.8 metres using specialised turret trucks. VNA delivers significantly higher storage density within the same footprint.
How do you design a warehouse layout for VNA forklifts?
Designing for VNA forklifts is a systematic process involving optimal racking configurations, guide rail installation for precise navigation and separated traffic flows to prevent bottlenecks. Professional site surveys are essential to confirm the floor can support racking loads.
How do I maximise vertical space in a logistics warehouse?
High-bay racking systems such as VNA pallet racking are the most effective method for maximising vertical space. These systems extend storage upwards rather than outwards. Combined with appropriate MHE such as turret trucks, you can use the full ceiling height for pallet storage.
What are the pros and cons of VNA racking systems?
The advantages are increased storage density, reduced footprint requirements and excellent selectivity for every pallet. The disadvantages include higher initial investment, the need for specialist MHE and guide rails, and slightly longer picking times compared to wide aisle systems.
How do I plan a high-density warehouse layout?
Planning a high-density warehouse layout is centred on assessing available height and floor space, selecting appropriate racking systems such as VNA or drive-in racking, optimising traffic flow and ensuring compliance with safety regulations. Professional design consultation is recommended.
What upgrades help logistics operations scale quickly?
Modular VNA racking systems designed for future expansion are among the most effective upgrades for rapid scaling. Wire mesh decking for improved safety and integrated guide rail systems are also valuable additions. Choosing systems with standardised components ensures you can increase capacity easily.
What kind of racking is best for growing logistics companies?
VNA pallet racking is often the best choice for growing logistics companies because it maximises storage capacity within existing premises, integrates with modern MHE and offers scalable configurations. This approach avoids costly relocations and supports increased throughput.
