Warehouse Modernisation & Upgrades: Outdated Storage Is Costing You Time, Space and Money.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.
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.
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
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If your warehouse operations are beginning to feel outdated, performance losses compound quickly.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.
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
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.
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
See The Difference Modernisation Makes
Project Spotlight
See how our customers are upgrading
3stepIT: Transforming Space and Efficiency with Automated Storage from Constructor Sweden
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.
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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