About Pella Brands

Pella Windows and Doors is a nationally recognized manufacturer known for producing high-quality, energy-efficient windows and doors for both residential and commercial applications. Their reputation is built on craftsmanship, innovation, and a commitment to excellence in every product they create.

With a strong operational presence in Miami, Pella’s local manufacturing facility plays a vital role in the company’s broader distribution network. As demand for their products continues to grow, the Miami facility has become an essential hub for ensuring timely production and delivery across various markets.

Pella is dedicated not only to superior product performance but also to optimizing their internal operations. Their proactive approach to improving logistics and storage demonstrates their commitment to operational excellence and customer satisfaction. Pella continues to lead the way in innovation and efficiency within the window and door industry.

Pella

Project Overview

Pella Windows and Doors is a nationally recognized manufacturer known for producing high-quality, energy-efficient windows and doors for residential and commercial applications. With a strong presence in Miami, Pella operates a manufacturing facility that plays a crucial role in their distribution network. However, as production volumes grew, the company faced a logistical challenge—how to efficiently store large, fragile window frames while maintaining easy access for workers.
Recognizing the need for a specialized storage system, Pella reached out to Atlantic Rack, to provide a customized racking system that would maximize space, improve accessibility, and ensure the safety of their window frames.

The Challenge

Pella Windows and Doors was dealing with a storage bottleneck that was negatively impacting their workflow. Storing window framing in traditional pallet racking systems was inefficient, as they are designed for standard-sized items and did not allow for easy retrieval or vertical stacking of oversized materials.
Selective racking is not ideal for storing window frames due to the unique dimensions and fragility of these items. Window frames are typically large, lightweight, and prone to damage from pressure or improper support. Selective racking, which is designed for palletized goods and uniform loads, lacks the specialized support needed to prevent bending, warping, or scratching of window frames. Additionally, the vertical storage configuration of selective racking can make it difficult to safely access individual frames without risking damage to adjacent items. A more suitable alternative would be cantilever racking or custom-built racks that provide horizontal support and easier handling for these delicate, oversized products.
Several key challenges had to be addressed:
  1. Storage Optimization – The manufacturing facility needed a way to store window frames without wasting valuable floor space.
  2. Ease of Access – Employees required a system that would allow them to quickly retrieve materials for manufacturing without delays.
  3. Damage Prevention – Window frames are delicate and require a storage solution that minimizes the risk of bending, scratching, or breaking.
  4. Scalability – Any implemented solution needed to be adaptable to accommodate future.
Cantilever Rack

The Solution: Cantilever Racks

After analyzing Pella’s facility and workflow requirements, Atlantic Rack recommended replacing traditional racking for STRUCTURAL CANTILEVER RACKING, a specialized solution designed specifically for long and oversized materials. This system would provide Pella Brands with an efficient way to store their window frames while ensuring easy access, space optimization, and durability.

Unlike traditional pallet racks, cantilever racking features an open-front design that allows for unobstructed access, making it ideal for handling long, bulky, delicate items like window and door frames. With heavy-duty load capacity and vertical space efficiency, the system was custom-tailored to Pella’s specifications for a seamless fit into their existing operations.

Implementation

The implementation process for installing cantilever racks to store window and door frames involved several key phases to ensure optimal functionality and safety. First, a thorough site assessment was conducted to evaluate the available space, floor load capacity, and workflow requirements. Based on this analysis, the custom racking layout design was developed, tailored to the dimensions and handling needs of the window and door frames. Once the design was approved, Atlantic Rack’s installation team prepared the site, by clearing the area, marking the anchor points, and ensuring level flooring.

The cantilever racks were then assembled onsite and securely anchored to the floor, with arms adjusted to accommodate varying frame sizes. After installation, the system was tested for stability and ease of access, and staff were trained on proper loading and unloading procedures. This structured approach ensured a smooth transition to a more efficient and protective storage solution.

Cantilever Rack Installation
Cantilever Rack Installation
Cantilever Rack Installation
Cantilever Rack

Results and Impact

The installation of cantilever racks brought significant improvement to Pella’s operational efficiency and space utilization. The new racking system allowed for vertical storage of long and bulky window frames, which previously occupied excessive floor space and were difficult to access. As a result, the company experienced a 40% increase in available warehouse space and a 25% reduction in handling time. This streamlined workflow not only enhanced worker safety by minimizing manual lifting and movement but also reduced the risk of product damage. Overall, the implementation of cantilever racks led to faster order fulfillment, improved inventory management, and a noticeable boost in productivity and cost savings.
Once fully integrated, Pella’s new storage system provided substantial improvements:
  • Enhanced Warehouse Efficiency – With a better storage layout, employees could access materials faster, reducing production delays.
  • Increased Storage Capacity – Maximized vertical space allowed Pella to store more window frames without cluttering the facility.
  • Reduced Risk of Damage – The cantilever racking system protected window frames from bending or breaking, reducing waste and costs.
  • Operational Scalability – The flexible design of the system ensured that future expansion could be accommodated with ease.

Conclusion

Through a strategic partnership with Atlantic Rack, Pella Windows and Doors successfully overcame their storage challenge, resulting in a more streamlined and efficient warehouse operation. The implementation of structural cantilever racking allowed Pella to significantly improve operational flow, safeguard their large and fragile window frames, and create a more scalable storage system to support future growth.

This tailored solution not only met their immediate needs but also reinforced the value of strategic planning in warehouse optimization. Atlantic Rack’s deep expertise in warehouse storage systems and their dedication to customized implementation reaffirmed their role as a trusted partner for companies seeking reliable, high-performance storage solutions.