10 Ways to Optimize Your Brownfield Facility

When it comes to warehouse and distribution center operations, many companies find themselves managing brownfield facilities — existing buildings that weren’t initially designed with today’s high-efficiency standards in mind. As businesses grow, brownfield operations must evolve to keep up with increasing demand, new customer expectations, and the drive for operational efficiency. While starting fresh with a greenfield facility may sound tempting, the reality is that optimizing your current brownfield facility can be a more cost-effective and strategic solution. Here are ten actionable ways to optimize your brownfield facility for better performance and scalability.

Evaluate Existing Infrastructure

Before making any changes, you should:

1. Conduct a comprehensive audit of your current infrastructure.
2. Analyze workflows, storage solutions, and equipment to identify areas of inefficiency.
3. Look for bottlenecks, outdated equipment, and underutilized space.

This initial assessment will provide a clear roadmap for where upgrades are necessary and what can be improved without a complete overhaul.

Leverage Automation Solutions

Automation is for more than just new facilities. There are plenty of cost-effective automation systems that can be retrofitted into existing spaces. From automated storage and retrieval systems (AS/RS) to autonomous mobile robots (AMRs), adding automation can significantly boost your picking accuracy and speed while reducing the reliance on labor. These systems can be installed with minimal disruption and immediately drive operational efficiencies.

Improve Space Utilization

One of the biggest challenges in brownfield facilities is maximizing space. Instead of expanding horizontally, think vertically. Solutions like mezzanines, vertical lift modules (VLMs), and more sophisticated racking systems can dramatically improve space utilization. Consider how much overhead space is underutilized and how smarter storage systems can consolidate your footprint, freeing up room for other operations.

Enhance Workforce Efficiency

An optimized facility not only focuses on systems and technology but also on its people. Streamline workflows to reduce unnecessary travel time within the facility. Tools like pick-to-light systems, voice-picking, and mobile workstations can make your workforce more productive. Additionally, cross training your staff can help reduce downtime and keep operations moving smoothly, even when staffing is tight.

Upgrade Material Handling Equipment

Material handling equipment, such as forklifts, conveyors, and automated guided vehicles (AGVs), can become outdated quickly, impacting your efficiency and cost-effectiveness. Consider investing in energy-efficient, modern equipment that offers faster performance and lower operational costs. Upgraded equipment will also provide better reliability and reduce the need for maintenance, ensuring smoother daily operations.

Utilize Warehouse Management Software (WMS)

Your warehouse management system (WMS) plays a critical role in optimizing your facility. If your current system is outdated or lacks the flexibility to integrate with modern technologies, it may be time for an upgrade. A robust WMS can streamline inventory management, improve order fulfillment accuracy, and provide real-time data to help you make informed decisions. Ensure your WMS can handle future automation expansions and other upgrades.

Implement Energy-Efficient Systems

Older facilities often have higher energy costs, but there are ways to mitigate this. By installing energy-efficient lighting, such as LEDs, along with automated systems to control HVAC and electricity use, you can significantly cut operational expenses. Implementing smart systems that monitor energy consumption in real time can provide insights into where further savings can be made without sacrificing performance.

Focus on Safety and Compliance

As you optimize your brownfield facility, it’s crucial to ensure that safety and regulatory compliance are top priorities. Regularly update your safety protocols to match new workflows and technologies. Ensure any new equipment or upgrades comply with local regulations and industry standards. This not only keeps your team safe but also helps avoid costly fines or penalties down the road.

Plan for Future Growth

Even as you optimize for today, keep tomorrow in mind. Whether you install modular racking systems or choose scalable automation solutions, make sure the upgrades you implement can easily accommodate future growth. Flexibility is key in any optimization strategy, ensuring your facility can evolve with changing business needs.

Collaborate with Expert Partners

Optimizing a brownfield facility can be complex, but you don’t have to do it alone. Working with industry experts who specialize in retrofitting and upgrading facilities can help you implement best practices and ensure you’re using the most effective solutions. From design consultations to turnkey project execution, the right partner can make the difference between a temporary fix and long-term success.

Optimizing your brownfield facility may seem daunting, but the potential rewards are worth the effort. You can transform your existing space into a high-performance operation by improving efficiency, reducing costs, and planning for future growth. Start today by evaluating your current setup and contacting one of our experts who can guide you through the process here.

Ready to take your warehouse to the next level? Contact us at Storage Solutions as your partner for expert advice and solutions tailored to your unique needs.