The growth of Brazilian retail has been accompanied by new logistical challenges. The pressure for short deadlines, product variety, and constant shelf availability has made warehouse layout a competitive differentiator. According to the Brazilian Institute of Geography and Statistics (IBGE), retail trade accumulated growth of 4.7% in 2024, marking the eighth consecutive year of gains. In the expanded retail sector, which includes vehicles, automotive items, construction materials, and wholesale food and beverages, the result was positive at 4.1%, higher than in 2023 (2.3%). Given the segment’s potential, operational efficiency has become vital to standing out in an increasingly competitive market.
For Giordania Tavares, CEO of Rayflex, a national leader in the manufacturing of high-speed doors in Brazil and Latin America, the impact of planning is direct on results: ‘When a warehouse layout is well-designed, it ensures better space utilization, reduces losses, and improves store replenishment flow, reflecting in the end customer’s shopping experience,’ she explains.
The layout model adopted varies according to the needs of each operation but must meet requirements such as material, equipment, and operator movement; proper item storage; storage capacity in terms of dimension and height for input placement; optimization of inbound and outbound flow; and cleanliness. Check out some efficient models:
- L-shaped format:This type of design is widely used because the docking areas are located at each end of the warehouse, while the stock is concentrated in the middle, at the 90-degree angle.
- I-shaped design:In this format, the operation is the simplest, as docking locations are at each end, with stored products in the center, allowing free movement of goods along with workers and machinery. It is recommended when the space is large and the product volume is also high.
- U-shaped format:Due to its simple and easily replicable design, it can be used in any type of location. It is advisable to place the docks side by side at the ends of the ‘U,’ while the product stock, positioned at the back, occupies the largest area of the warehouse in the semicircular part of the letter.
These formats help organize aisles, stock, and loading/unloading areas according to the volume and diversity of goods. ‘When combined with technological resources, such as warehouse management systems (WMS), digital addressing, and automatic high-speed doors, these models ensure agility, safety, and traceability throughout the chain. The installation of customized automatic high-speed doors, for example, ensures proper sealing and contributes to the smooth flow of people in each environment, respecting the specificities of the location and directly influencing logistical operations,’ evaluates the expert.
The consumer may not see the warehouse, but they feel its effects: stocked shelves, greater variety, and on-time deliveries.“The layout has ceased to be just an operational detail and has become strategic for retail success. It is directly linked to brand loyalty and competitiveness,’ concludes Giordania.
