The growth of Brazilian retail has come with new logistical challenges. The pressure for short lead times, product variety, and constant shelf availability has made warehouse layout a competitive differentiator. According to the Brazilian Institute of Geography and Statistics (IBGE), retail sales accumulated 4.7% growth in 2024, marking the eighth consecutive year of gains. Expanded retail, which includes vehicles, automotive parts, construction materials, and food and beverage wholesalers, saw a positive 4.1% growth, higher than in 2023 (2.3%). Given the segment’s potential, operational efficiency has become vital to differentiate itself in an increasingly competitive market.
For Giordania Tavares, CEO of Rayflex, a national leader in the manufacture of high-speed doors in Brazil and Latin America, the impact of planning is direct on the results: “When a warehouse layout is well designed, it ensures better use of space, reduces losses, and improves the supply flow in stores, reflecting on the end customer’s shopping experience,” he explains.
The layout model adopted varies according to the needs of each operation, but must meet requirements such as: movement of materials, equipment, and operators; proper storage of items; storage capacity in terms of dimensions and height for the arrangement of supplies; optimization of inflow and outflow; and cleanliness. Check out some efficient models:
- L-shaped: This type of design is widely used, as the dock areas are located at each end of the warehouse, while the stock is concentrated in the middle, where the 90º angle occurs;
- Design em I: This format is simpler to operate, as docks are located at each end and all products are stored in the center, allowing for the free movement of goods with the movement of employees and machinery. It is recommended when the space is large and the volume of products is also high;
- U-shape: Due to its simple and easily replicable design, it can be used in any type of location. It is recommended to place the docks side by side, at the ends of the “U,” while the product stock at the back occupies the largest area of the warehouse, in the semicircle of the letter.
These formats help organize aisles, stocks, and loading and unloading areas according to the volume and diversity of goods. “When combined with technological resources such as inventory management systems (WMS), digital addressing, and automatic high-speed doors, these models ensure agility, safety, and traceability throughout the supply chain. The installation of custom-made automatic high-speed doors, for example, provides proper sealing and contributes to the agility of the flow of people in each environment, respecting the specificities of the location and directly influencing the results of logistics operations,” explains the expert..
The consumer may not see the warehouse, but they feel its effects: stocked shelves, greater variety and on-time deliveries.. “Layout is no longer just an operational detail; it has become strategic to retail success. It’s directly linked to brand loyalty and competitiveness,” concludes Giordania.
