Project Overview

The Chengdu project for CloudHorizon Fulfillment was not a generic shelving replacement. It was a focused redesign of a regional fulfillment hub processing beauty products, snacks, household items, and campaign-driven e-commerce inventory. The client needed a system that could carry daily operational pressure while improving how shoppers, operators, or warehouse teams understood the space at a glance.

Runda Rack began by studying the existing movement pattern, receiving rhythm, product mix, and points where staff lost time. The final brief centered on carton flow racks, selective pallet storage, pick-face zoning, replenishment lanes, and shuttle-ready structural planning. That meant the rack system had to act as infrastructure, merchandising tool, and workflow guide at the same time.

Client & Market Context

Chengdu is a demanding operating environment. Space is expensive, turnover is fast, and managers cannot solve capacity problems simply by adding more floor area. For CloudHorizon Fulfillment, commercial pressure came from more product variety, tighter operating windows, and the need to keep the site visually controlled even during busy periods.

The market context also shaped the engineering choices. A e-commerce intelligent warehouse requires fixtures that can be adjusted without calling a contractor for every seasonal or operational change. A successful system had to reduce hidden labour: fewer emergency shelf moves, clearer category ownership, faster cleaning, and more predictable replenishment.

The Challenge

The most important challenge was that daily order profiles changed sharply during livestream events and shopping festivals, causing fast movers to run out at pick faces while slow movers occupied prime locations. This was not only a design issue; it affected daily labour, safety, and sales productivity. When shelving does not match the real workflow, staff compensate with temporary stacks, blocked aisles, handwritten labels, and repeated handling.

A second challenge was continuity. The site could not be treated as an empty new build. Existing inventory, staff routines, customer access, forklifts, deliveries, or production shifts had to be respected. The new system needed to fit into a live business environment and create improvement without unnecessary downtime.

Engineering Solution

Runda Rack specified A/B/C velocity zones, carton-flow lanes for fast movers, reserve pallets behind replenishment paths, and rack lines compatible with future automation. The design team translated the operational brief into specific rack heights, bay widths, shelf depths, protection accessories, finish choices, and label positions. Every decision was tied to the way goods move through the site rather than to a catalogue default.

The layout separated high-frequency and low-frequency zones, clarified the difference between display, reserve, inspection, and dispatch positions, and protected the areas most likely to receive impact or heavy handling. Retail presentation focused on sight lines and premium finishes; factory and warehouse areas focused on load paths, forklift radius, batch control, and safe access.

Installation & Delivery

The implementation team tested slotting assumptions with order data before installation, then moved SKUs into the new layout by velocity group over one weekend. Before full rollout, the team reviewed dimensions, access paths, and installation order with the client’s operations staff. Components were sorted by zone and labelled so crews could move directly from unloading to assembly without searching for parts on site.

The installation sequence was deliberately practical. Critical operating areas were completed first, then secondary zones were migrated after the team confirmed that replenishment, picking, cleaning, or customer circulation worked as intended. This reduced rework and allowed managers to train staff on the new logic as each section came online.

Business Impact

Pickers walk less, replenishment teams refill active faces without blocking packing lanes, and managers can re-slot campaign products before demand spikes. The measurable result was not only more capacity; it was better control of the space. Teams could see what belonged where, identify exceptions earlier, and move products or materials with fewer unnecessary touches.

The headline metrics for this project were Picking Speed +33%, Replenishment Interruptions -37%, Automation-ready Rack Lines. These figures reflect the practical value of matching shelving design to the real operating model. Capacity matters, but capacity becomes valuable only when staff can replenish, inspect, pick, clean, and reconfigure the system without slowing the business down.

Long-Term Value

CloudHorizon gained a layout that works today with manual picking and can evolve toward automated movement as order volume grows. The project also gives the client a clearer standard for future upgrades. Instead of treating racks as isolated furniture purchases, the business now has a repeatable layout logic that connects space planning, safety, merchandising, and operational discipline.

For Runda Rack, this case shows why project-specific design matters. A supermarket, a convenience chain, an electronics factory, a food plant, and a port warehouse cannot be solved with the same copy-and-paste rack specification. The best result comes from reading the site first, engineering the system around the work, and delivering a structure that remains useful long after installation day.