UPGRADES & MODERNISATION

Warehouse Modernisation & Upgrades: Outdated Storage Is Costing You Time, Space and Money.

Optimise your warehouse operations with targeted storage system upgrades that integrate seamlessly with manual and automated systems.

Start your upgrade assessment View results from real retrofit projects

UPGRADE YOUR SUPPLY CHAIN

Warehouse Modernisation & Upgrades

If your warehouse is facing increasing pressure, consider targeted modernisation and strategic retrofits rather than building new. These upgrades can improve performance, extend asset lifespan, and future-proof operations while protecting your investment.

6-18 months

For a return on your investment

40-80%

Capacity increase on average

Up to 48%

Cheaper than building new

Advantages at a Glance

How to quickly maximise your warehouse performance

Upgrade your Warehouse

Upgrading your warehouse can help you store more items, keep everything safer, and make your equipment last longer, all within your current space. By reorganising the layout and updating your systems to meet changing needs, you can boost your warehouse's performance without the high costs, disruptions, or headaches that come with relocating or constructing a new building.

Retrofit Vs New Build Warehouses

Retrofit programs are a great option if you're looking to improve your facilities without starting from scratch. They help you save time and money while also being more environmentally friendly. With these programs, you can modernise your space more quickly and sustainably, improving efficiency, regulatory compliance, and readiness for future needs. All within your current warehouse setup.

What Warehouse Modernisation Means For You

As your storage ages, you might consider upgrading or retiring systems to keep up with increasing operational and compliance needs.

Warehouse modernisation is a strategic upgrade of your existing storage infrastructure, layout, and systems to meet your current requirements. It enhances safety and efficiency by creating systems designed for future automation, all without high costs, downtime, or the risks of building anew. Unlike simply replacing racking, a retrofit takes a holistic approach to your operations, considering flow, software, accessibility, compliance, and scalability.

It delivers the performance of a new build while maintaining your existing footprint, workflows, and investments.

What can you modernise:

Storage Systems
Layout & Configuration
Safety Systems
Automation Readiness
Controls & Software

WAREHOUSE RED FLAGS

Is It Time To Upgrade Your Warehouse?

If your warehouse operations are beginning to feel outdated, performance losses compound quickly. An upgrade is often the most cost effective response when...

Order volumes, SKU profiles, or picking methods have changed.

The storage capacity is limited, even though there is available vertical space.

Existing racking no longer meets compliance standards, like EN15635.

Safety risks or rack damage are increasing maintenance costs.

Automation or WMS upgrades are planned, but the layout is incompatible.

Relocation or new build costs cannot be commercially justified.

THE CHALLENGE

Why Your Warehouse Could Be Struggling Right Now...

Your warehouse is under constant pressure to deliver. Not just packages, but results.

Logistics and Supply Chains are demanding

Several structural forces are driving this disconnection:

Higher SKU complexity
Lightning-fast picking speeds
Zero safety incidents or concerns
Easy integration with automated systems
Customer expectations for speed and accuracy

SATISFIED CUSTOMERS

Examples Of Modernisation Projects

Le Klint

Grafisk Maskinfabrik

KJV

Danfoss

Toft Care

UPGRADE YOUR WAREHOUSE. STABILISE YOUR SUPPLY CHAIN.

How Your Business Can Benefit From Warehouse Modernisation

The fastest route to grow your performance with a future-proof warehouse!

Increase in capacity without expanding

Optimised layouts and upgraded racking systems designed to unlock unused floor space. Up to 40% boost in storage capacity without expanding footprint.

Minimal disruption to live operations

Warehouse modernisation projects delivered using phased installation programmes, allowing warehouses to remain operational throughout.

Automation ready by design

Storage upgrades planned to support future automation, AMRs and evolving SKU profiles without structural change.

Upgrades aligned with compliance standards

All warehouse solutions are designed to meet load performance, rack inspection, and safety standards, ensuring full compliance with EN15635.

Faster return on investment

Many warehouse upgrade projects deliver ROI within 6-18 months, depending on the scope and the gains in throughput.

Over 80 years of engineering expertise

Supporting warehouse modernisation and upgrade projects across Europe and globally, engineered for safety, compliance and long-term performance.

COMPARISON

Retrofit vs Upgrade vs New Build

For most operational warehouses, retrofits and upgrades delivers faster ROI with lower risk.

RETROFITS

Primary Objective - Adapt and strengthen existing systems
Scope - Structural or layout changes to existing storage systems
Capital Cost - Moderate
Project Timeline - Weeks to Months
Operational Disruption - Phased, Minimum
Sustainability Impact - Lower by extending system lifespan
Best Suited For - Facilities nearing capacity or needing layout changes

UPGRADES

Primary Objective - Improve performance, safety or technology within current systems.
Scope - Component or system level enhancements
Capital Cost - Low to moderate
Project Timeline - Days to Weeks
Operational Disruption - Minimal
Sustainability Impact - Low, extends lifespan of existing assets
Best Suited For - Warehouses needing targeted performance improvements

NEW BUILDS

Primary Objective - Develop a completely new warehouse facility
Scope - Full design, construction and system installation
Capital Cost - Very High
Project Timeline - 12-36 Months
Operational Disruption - Major disruption or relocation needed
Sustainability Impact - Highest environmental impact due to new construction and land use
Best Suited For - Businesses needing major relocation or scale expansion

BEFORE & AFTER

See The Difference Modernisation Makes

BEFORE

Facilities before upgrading and expanding

AFTER

High-density layouts, strengthened structures,

safer aisles, efficient picking and packing

CUSTOMER STORY

Project Spotlight

See how our customers are upgrading

3StepIT & Constructor Sweden - Tornado VLM

RETROFIT PROJECT

3stepIT: Transforming Space and Efficiency with Automated Storage from Constructor Sweden

When fast‑growing circular‑IT provider 3stepIT outgrew its warehouse capacity, it turned to our Swedish team for a smarter, more space‑efficient solution. Installing two Tornado vertical lift machines enabled them to reduce their traditional shelving footprint from 250 m² to just 40 m² of high‑density vertical storage. The upgrade boosted efficiency by 200%, dramatically cutting error rates and creating a scalable foundation for continued growth so effective that a third machine is already on its way.

+ 200% Efficiency Boost

250m² to 40m² Reduction in footprint

84% Footprint reduction

Information Technology Retrofit Consolidation Sweden

Read Full Case Study

"We were growing so fast that we were literally running out of floor space. We knew we either had to expand our building footprint, which wasn't feasible, or completely rethink how we were storing equipment."

Andreas Agnesson

Site Manager

3stepIT

DEXION RETROFITS

A Modernisation Journey Designed Around Your Operations

Our warehouse retrofit and upgrade process explained

We support every stage of transformation - From first inspection to final sign-off

Warehouse Assessment

EN15635 audit, structural evaluation, capacity analysis, workflow mapping.

Warehouse Planning

Phased installation timetable designed to maintain full operational continuity, creating minimal disruption.

Warehouse Implementation

Our own installation teams deliver upgrades with precision, safety in mind and zero downtime for your operations.

Support & Service

Predictive maintenance & inspections, tailored service packages, and easy access to spare parts.

FAQ'S

Your Frequently Asked Questions

How much does a warehouse modernisation cost?

Every warehouse upgrade project is unique; the costs depend on the size of the warehouse, existing infrastructure, storage system types and the scope of upgrades. Retrofit projects are typically significantly more cost-effective than new builds and deliver ROI faster. If you want to learn more about costs, we can review your project to assess the expenses.

How long does an upgrade project take?

Project timelines can vary, but most retrofits are completed faster than new builds due to reduced planning and construction requirements.

What is a warehouse retrofit?

A warehouse retrofit involves upgrading existing storage systems, layouts and safety components to improve capacity, efficiency and compliance. All without the need to build a new facility or relocate operations.

What does a warehouse modernisation typically include?

A retrofit can include upgrades to shelving and racking, reconfigurations of existing layouts, floor-loading assessments, safety enhancements, and future-proofing for automated systems.

What types of warehouses are suitable for a retrofit?

Most warehouses, including distribution centres, manufacturing sites, and e-commerce fulfilment facilities, are suitable for retrofitting. Providing the building structure and floor loading support the upgrade.

Is a warehouse retrofit cheaper than building new?

Yes. Retrofitting avoids buying land, planning permission and relocation costs - making it a more economical solution in most cases.

Will a warehouse retrofit disrupt operations?

Retrofit projects are typically delivered in phased installations, allowing your operations to continue with minimal downtime.

Can retrofits be carried out while the warehouse is operational?

Of course! With careful planning and a phased execution, upgrades can be completed while maintaining day-to-day activities at your site.

Does warehouse retrofit improve safety and compliance?

Yes. Retrofits often include site surveys, load compliance checks, and safety accessories and layout improvements aligned with current regulations.

Can existing racking be reused or modified?

In many cases, your existing racking can be reconfigured or enhanced rather than replaced entirely, depending on its condition and compliance with regulations and safety standards.

Can a warehouse upgrade prepare my site for automation?

Retrofits and upgrades can optimise layouts, aisle widths, and load tolerances to support automation, conveyors and autonomous mobile robots (AMRs).

Why should I choose Dexion for warehouse retrofit and upgrades?

Dexion combines engineering expertise, compliance standards, and proven retrofit experience to deliver safe, scalable warehouse upgrades with minimal disruption.

Still got more questions? Our expert team is happy to help!

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