High-Density Industrial Storage & Racking Solutions

Multi-Level Picking Gallery Manufacturers & Factory serving Verona

Whitepaper: Engineering Multi-Level Picking Galleries for Verona's Industrial Transformation

In modern industrial logistics, floor space is the most valuable and costly asset. This is especially true for the Verona logistics sector, which stands as a core intermodal freight hub in Southern Europe (Quadrante Europa). As global supply chains face volatile lead times, localized warehouse capacity must expand without increasing the facility's footprint. This whitepaper analyzes the mechanical engineering, safety parameters, and supply chain strategies involved in constructing highly efficient Multi-Level Picking Galleries designed to meet the strict demands of European and Italian warehouse safety standards.

"By converting overhead air space into active work zones, Multi-Level Picking Galleries double or triple structural storage density, enabling e-commerce, third-party logistics (3PL), and manufacturing firms in Verona to handle up to 300% more inventory within their existing physical envelope."

1. The Industrial and Logistics Landscape of Verona, Italy

Located at the intersection of the primary Brenner Motorway (connecting Northern and Southern Europe) and the East-West Mediterranean Corridor, Verona is the logistical backbone of Northern Italy. Logistics complexes such as the Quadrante Europa handle massive volumes of automotive parts, agricultural and food processing materials, pharmaceuticals, and manufacturing imports. Due to stringent regional environmental zoning laws and high municipal land development fees in Verona, building new warehouse extensions is costly and time-consuming.

Consequently, local operators are prioritizing vertical optimization. The design of structural steel mezzanine flooring, multi-tier shelving systems, and automated sorting galleries must adapt to local seismic zoning laws. Under the Italian National Construction Technical Standards (NTC 2018), Verona is categorized with specific seismic risk levels, requiring localized structural calculations, structural bracing (X-bracing and K-bracing), and high-tensile steel anchor bolts to ensure personnel safety under dynamic seismic and operational loads.

2. Technical Anatomy of a Multi-Level Picking Gallery

A multi-level picking gallery is a complex engineering structure integrating heavy-duty industrial pallet racking with structural walkways, staircases, and safety gates. Unlike standard storage racks, a picking gallery features integrated floor levels that support human pickers, autonomous mobile robots (AMRs), and overhead conveyors.

  • Structural Columns and Uprights: Roll-formed from structural steel grade S355JR or high-yield strength steel sheets, designed to carry both the dead load of the mezzanine system and the live load of picking operations (ranging from 250 kg/m² to over 1000 kg/m²).
  • Floor Beams and Purins: Engineered to minimize vertical deflection (exceeding L/300 limits) and to eliminate structure-borne vibrations, ensuring a stable platform for operators and sensitive dynamic scales or automated pick-to-light equipment.
  • Walkway Decking Options: Options include heavy-duty steel gratings for fire safety (allowing sprinkler water to pass through), embossed steel plates for high traction, or high-density timber panels lined with flame-retardant composites.
  • Safety Handrails and Kickplates: Compliant with European standard EN ISO 14122-3, featuring continuous handrails, intermediate rails, and minimum 100mm kickplates to prevent tools or parts from falling to lower levels.

3. Global Trends in High-Density Fulfillment

Globally, warehouses are shifting from static, slow-moving storage toward high-throughput, omni-channel micro-fulfillment centers. In these environments, pickers must access thousands of Stock Keeping Units (SKUs) in minutes. The integration of Pick-to-Light (PTL) arrays, 3D automated put-walls, and automated sorting systems allows for high accuracy and rapid dispatch. By pairing heavy-duty steel multi-level galleries with automated logistics systems, operators can reduce cycle times from order receipt to shipping down to less than 15 minutes, maintaining a competitive edge in European logistics networks.

China Factory 4.0: Delivering High Quality, Structural Integrity & Supply Chain Resilience

For procurement officers in Italy and across the European Union, sourcing industrial steel structures involves assessing manufacturing standards and lead-time stability. As a premium manufacturer, Nanjing Lush Rack Co., Ltd. integrates China’s Industry 4.0 manufacturing processes to deliver high-quality products to the European market. Our production facility features high-precision automated systems designed to minimize variances and ensure structural integrity:

  • Automated Laser Cutting & Roll-Forming: Our high-speed laser cutting machinery ensures precision down to 0.1mm, guaranteeing clean bolt alignment and quick installation on-site.
  • Robotic MIG/TIG Welding Systems: Structural integrity depends on high-quality weld joints. Our robotic welding lines provide deep penetration and uniform welds, exceeding the ISO 3834 standard for international structural steel welding.
  • Electrostatic Powder Coating Line: We use an automated chemical pre-treatment and electrostatic powder coating process. This ensures robust corrosion protection, key for cold chain and high-humidity warehouse environments.
  • Structural Steel Traceability: All raw materials are sourced from leading Chinese steel mills, complete with mill test certificates (MTC) conforming to European standard EN 10204 3.1.

Nanjing Lush Rack Production Line & Processes

Steel Cutting Process
Cutting
Welding of the Crossbeam
Welding of the Crossbeam
Plate Welding
Plate Welding
Column Welding
Column Welding
Painting Process
Painting Process
Packing Process
Packing Process
Automatic Cutting Machine
Automatic Cutting Machine
Precision Cutting Machine
Cutting Machine
Automatic Welding Machine
Automatic Welding Machine
Welding Station
Welding Machine
Packing Machine
Packing Machine

About Nanjing Lush Rack Co., Ltd.

Nanjing Lush Rack Co., Ltd. is a professional manufacturer specializing in industrial storage racking systems and warehouse storage solutions. The company is dedicated to the research, design, production, and installation of a full range of warehouse racks and shelving systems, providing efficient and reliable storage infrastructure for modern logistics and supply chain operations.

With strong engineering capabilities and advanced manufacturing equipment, Nanjing Lush Rack Co., Ltd. is able to deliver complete warehouse racking solutions from concept design and structural calculation to production, quality inspection, and installation guidance. Our engineering team works closely with clients to analyze warehouse space utilization, material flow, and load requirements, ensuring that each solution is safe, stable, and cost-effective.

The company maintains a strict quality control system throughout the production process, from raw material selection to final product inspection. All racking systems are designed and manufactured to meet international safety and durability standards, ensuring long service life and reliable performance even under heavy industrial use.

Nanjing Lush Rack Co., Ltd. has a skilled technical team and an experienced sales department that provides responsive communication and professional support. With stable production capacity and efficient supply chain management, we are capable of handling both standard orders and large-scale customized projects with consistent quality and on-time delivery.

Our products are widely used in industries such as logistics and distribution, e-commerce fulfillment centers, manufacturing, automotive parts storage, cold chain logistics, and retail warehousing. We have established a strong customer base across domestic markets in China, and our products are also exported to Southeast Asia, Europe, North America, and other international regions.

As a trusted partner in warehouse storage solutions, Nanjing Lush Rack Co., Ltd. is committed to delivering high-quality racking systems, innovative storage concepts, and long-term value for our customers. We continue to focus on improving warehouse efficiency, reducing operational costs, and supporting the development of modern intelligent logistics systems.

15+
Years Engineering Exp.
500+
Global Projects Completed
99.8%
On-time Delivery Rate
100%
EN 15635 Safety Standard

Frequently Asked Questions

What structural standards do Nanjing Lush Rack systems comply with for use in Italy?
Our multi-level picking galleries and industrial storage systems are engineered in strict accordance with European racking design codes, specifically EN 15512 (Steel static storage systems - Adjustable pallet racking systems - Principles for structural design) and EN 15635 (Application and maintenance of storage equipment). For projects in Verona and other regions in Italy, we calculate wind, dead, dynamic, and seismic loads based on Italy’s NTC 2018 (Norme Tecniche per le Costruzioni) structural code.
How does a Multi-Level Picking Gallery improve warehouse picking efficiency?
Multi-level galleries create multiple horizontal floor tiers within the vertical space of the warehouse. By dividing a high-ceiling facility into independent picking tiers, travel time for picking operators is reduced by up to 60%. Pickers work within assigned levels, which are serviced by vertical lifts, spiral chutes, or automated conveyors. This prevents congestion and allows several orders to be picked simultaneously, boosting throughput in high-velocity operations.
What are the safety measures in place for multi-tier picking structures?
Safety is built into every element. Walkways feature continuous industrial safety handrails, safety mid-rails, and bottom kickplates to prevent items from falling. Pallet drop zones are equipped with self-closing or rotating pallet gates to protect personnel during loading. Flooring materials are chosen for anti-slip ratings and fire resistance, allowing standard building sprinkler systems to function properly.
Can these racking systems integrate with automated machinery and ASRS systems?
Yes, our racking systems are designed to integrate with automated storage and retrieval systems (ASRS), autonomous mobile robots (AMRs), pick-to-light (PTL) configurations, and dynamic gravity flow tracks. The structural tolerances of our upright posts and beams are kept minimal, ensuring alignment for automated sensors and robotic guidance paths.
What is the estimated delivery and installation timeline for Verona warehouse projects?
Typically, manufacturing takes 4 to 6 weeks from structural drawing sign-off to loading. Ocean freight transport from our Chinese production plant to the Port of Venice or Trieste, followed by overland delivery to Verona, takes approximately 4 to 5 weeks. On-site installation is carried out by local teams or guided by our remote engineering team, depending on the complexity of the project.

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