Not all products move at the same pace. While managing a warehouse or distribution centre in New Zealand, you may notice that some items fly off the shelves every week or even every day, while others stay in storage for months before they’re picked. 

Read also: How Inventory Financing Helps Early-Stage Logistics Startups Keep Goods Moving

Recognising these differences gives you the chance to adjust your storage layout so that each type of inventory is placed where it makes the most sense. Keeping both fast-moving and slow-moving inventory in mind while designing your storage layout lets you use your space better and make your facility run more efficiently while saving on costs. Plus, with a proper and efficient pallet racking system in place, you’ll have an easier time organising your storage space in a way that accommodates products moving at different paces. This sets the stage for a warehouse setup that supports both day-to-day efficiency and long-term flexibility. In this article, we’ll share a few tips you can take into consideration.

Prioritise Accessibility and Speed for Fast-Moving Inventory

Fast-moving inventory refers to items with high demand that need to be picked, packed, and shipped quickly. Accommodating the rotation of these goods means adopting a warehouse layout that reduces the time it takes to retrieve these items while also allowing space for regular replenishment. 

When storing fast-moving goods, your main consideration is accessibility. In-demand products should be located close to dispatch areas and picking stations to minimise transport time. This is particularly important in busy hubs like Auckland or Christchurch, where same-day or next-day delivery expectations are high. Safety also comes into play, since the zones where high-turnover products are stored experience heavy traffic from staff and equipment, like forklifts and lorries. Clear pathways and well-designed layouts implemented by pallet racking NZ providers can also help improve workflow efficiency without sacrificing safety. 

Here’s a list of best practices when designing warehouse layout for fast-moving inventory:

• Use golden zones: Place high-demand products between waist and shoulder height so workers can pick them without unnecessary bending or reaching. This reduces strain from repeated movements, plus it speeds up the process.
• Store close to dispatch: Position fast movers near packing areas or loading docks to cut down the distance travelled during picking. 
• Adopt flow racks or carton live storage: These dynamic racking systems allow for quick stock rotation and easy replenishment by loading new stock at the back and placing the items to be picked up in front.
• Keep aisles wide and uncluttered: Fast-moving goods attract frequent traffic, so wide aisles help forklifts and staff move safely without congestion.

Designing your layout with these points in mind allows you to ensure that your fast-moving products are handled with speed, safety, and efficiency.

Focus on Space Optimisation for Slow-Moving Inventory

Compared to fast-moving goods, slow-moving inventory doesn’t need the same level of accessibility. These items are picked less frequently, so your goal is to store them in a way that conserves space while keeping them organised and traceable. Slow-moving products can be stored further away from dispatch areas or in higher positions within your pallet racks. However, accuracy is essential, as losing track of a slow mover can become a costly or time-consuming ordeal when it’s finally needed.

Consider these best practices when allotting space for slow-moving inventory in your warehouse:

• Use vertical space: Store slow movers in higher rack levels to free up prime ground-level positions for fast movers. This helps maximise your storage footprint.
• Position away from main aisles: Keep slow-moving items in less accessible zones since they don’t need constant handling. This reduces congestion in busy areas.
• Label and track carefully: These items are picked less often, so it’s easy to lose track of them. Strong labelling and accurate warehouse management systems ensure you can locate slow-moving goods quickly when needed.
• Optimise pallet racking design: Use selective pallet racks or drive-in racking for slow-moving stock, which can store items densely without requiring constant access.

This way, you use your available space more efficiently while still ensuring slow movers are easy to find when it’s time to ship them.

Combining Fast and Slow Movers in One Layout

Most New Zealand warehouses deal with a mix of both fast- and slow-moving stock. The challenge is designing a layout that balances efficiency with space optimisation. You don’t want slow movers taking up valuable prime locations, but you also don’t want them buried so deeply that they become difficult to access.

A common approach is to zone your warehouse. Fast movers can be placed in the most accessible pallet racks, close to dispatch areas, while slow movers are stored in higher or more distant racks. Applying an ABC analysis can also help:

• A-items (fast movers) go near the dispatch points.
• B-items (moderate movers) occupy middle-ground positions.
• C-items (slow movers) are stored in the least accessible areas, often higher up or at the back of the facility.

Updating your inventory classifications regularly lets you adjust your layout as demand shifts and ensures you’re always making the best use of space and accessibility. Many NZ businesses are also making use of advanced warehouse management systems that integrate with local freight schedules. These solutions help them plan stock placement based on seasonal demand or regional distribution.

Why Getting It Right Matters

When you design your storage layout with both fast- and slow-moving inventory in mind, you create a warehouse that works smarter, not harder. Fast movers stay accessible, reducing wasted time and effort, while slow movers are stored efficiently without taking up valuable floor space. Using smart layout strategies, coupled with solutions from the right provider of pallet racking, New Zealand businesses can empower their teams to pick faster and to keep their storage areas organised, all while making safety a priority. For your business, that means smoother operations, lower costs, and a warehouse setup that can grow with your needs.