Stacole Wines Pick Module

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About Company

Stacole Fine Wines is a premier wine distributor based in Florida, known for offering an exceptional portfolio of fine wines and spirits sourced from around the world. Serving restaurants, retailers, and hospitality clients, Stacole Fine Wines has built its reputation on quality, expertise, and dedicated customer service. With a focus on curated selections and timely delivery, the company’s operations demand precision, efficiency, and flexibility—particularly within its warehouse and distribution infrastructure. As order volumes grew and product diversity expanded, the company recognized the need for a more advanced solution to streamline fulfillment and maintain its high service standards.

To keep pace with evolving market demands and to support continued growth, Stacole Fine Wines invested in a new warehouse facility. This presented the perfect opportunity to reevaluate and enhance their material handling strategy. The goal was clear: design a system that could handle high SKU counts, support a wide range of packaging sizes, and improve both speed and accuracy across all picking operations. That’s where Atlantic Rack came in.

Project Background

Atlantic Rack was brought in to design and install a custom Pick Module System that would align with Stacole’s operational goals and warehouse layout. Working closely with the Stacole team, Atlantic Rack engineered a multi-level solution centered around efficiency, flexibility, and intelligent space utilization. At the heart of the project was a modular pick module integrated from Interlake Mecalux racking, Mallard Manufacturing Carton and Pallet Flow Systems, and Ryson International Spiral Conveyors—components chosen for their durability, performance, and adaptability. The installation was strategically designed to support high-throughput picking zones, reduce employee travel time, and allow simultaneous picking operations, all while maximizing the available vertical space in the warehouse.

Seasonal fluctuations and promotional orders further complicated operations, highlighting the need for a flexible infrastructure that could adapt on the fly. Stacole Wines needed a solution that could not only handle high product variety but also streamline processes to improve accuracy, efficiency, and worker safety—without compromising on storage density.

The Solution

To solve the operational challenges Stacole Wines faced, Atlantic Rack delivered a fully customized, high-efficiency PICK MODULE designed specifically for the demands of wine distribution. At the core of the system was a multi-level structure built using Interlake Mecalux Racking, chosen for its strength, adaptability, and long-term durability. The system was integrated with Mallard Manufacturing Carton and Pallet Flow lanes, allowing inventory to be automatically fed forward as items were picked. This gravity-driven replenishment kept products easily accessible at all times, reducing the need for manual restocking and limiting picker movement.

The structure also prioritized modularity and future scalability. Shelving and flow lanes were adjustable to accommodate changes in product size, packaging, or demand. Multiple levels were connected by safe, well-placed stairways, allowing teams to pick in parallel across different zones without bottlenecks. Open floor space below the pick module was preserved for packing, staging, or overflow storage.

Implementation

Installing the Pick Module at Stacole’s facility required close coordination between Atlantic Rack and the warehouse team. The layout was carefully designed to separate full-case and split-case picking, with Gravity systems placed on all levels of the Pick Module. Clear picking aisles, staircases, conveyors and safety rails were integrated to allow efficient movement between levels.

One key challenge was optimizing the space without disrupting staging and packing zones. Atlantic Rack addressed this by sequencing the installation and adjusting the design in real-time to fit within the warehouse footprint. The result was a smooth build process completed on schedule and ready for immediate use. Pick paths, stairwells, and staging areas were installed with ergonomics and efficiency in mind, while safety barriers, guardrails, and netting were added to protect workers across levels. Despite the scale and intricacy of the system, the installation was completed on schedule and with minimal disruption. The result was a fully operational, high-throughput picking system ready to meet Stacole’s demanding distribution schedule from day one.

Results and Benefits

The new pick module brought immediate improvements to Stacole’s warehouse performance. Order fulfillment became significantly faster, with products organized by demand and easily accessible across multiple picking zones. Picker travel time was reduced, and multiple orders could be processed at once without bottlenecks. The system also improved inventory accuracy, with better product visibility and consistent placement, reducing picking errors and supporting barcode scanning. Vertical storage and modular design maximized space, accommodating a wide variety of packaging—from individual bottles to full cases—while freeing up floor space for other operations. The solution also introduced greater flexibility, allowing for seasonal adjustments and future expansion.

Overall, the new system lowered labor costs, reduced product damage, and improved workplace safety by minimizing strain and congestion—delivering the efficiency and scalability Stacole Wines needed to support its growing business.

Conclusion

Stacole Fine Wines’ investment in a customized pick module system marked a turning point in the efficiency and scalability of their warehouse operations. With Atlantic Rack’s expert design and implementation, the company has gained a tailored solution that supports faster order fulfillment, improves inventory control, and maximizes space—all while creating a safer and more flexible working environment. The project not only solved immediate logistical challenges but also positioned Stacole Wines for continued growth in a competitive and fast-moving industry. This case stands as a clear example of how smart warehouse design can directly elevate business performance.