Overview
Truflo Pumping Systems required a scalable, high-capacity storage solution for their new facility in the Coolum Industrial Estate. The brief extended beyond standard racking. The goal was to create a structured, efficient workspace that could support growth, improve accessibility, and maximise vertical space.
Storeplan delivered a complete, planning-led fit-out, integrating a multi-tier mezzanine system, pallet racking, and workbench zones into a cohesive and compliant storage environment.
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- The Challenge
The Challenge
Truflo’s new warehouse presented strong potential but also required careful planning to ensure it operated efficiently from day one.
Key challenges included:
- Maximising vertical space within a limited footprint
- Creating structured storage zones for a wide range of parts and components
- Balancing shelving and pallet storage in one integrated layout
- Ensuring safe access across multiple levels
- Future-proofing the layout to support business growth
Additionally, the solution needed to maintain workflow efficiency, allowing staff to move easily between picking, storage, and dispatch areas without disruption.
The Solution
Storeplan designed and delivered a multi-tier, rack-supported mezzanine system, forming the foundation of the entire fit-out.
1. Multi-Tier Mezzanine Storage System
At the core of the solution was a 74m² rack-supported mezzanine, engineered for performance and safety:
- 5kPa load-rated structural floor (500kg/m²)
- 5400mm upright frames maximising vertical capacity
- Dual-level shelving configuration for high-density storage
- 19mm structural ply flooring with steel support system
- Integrated DV201 rollover pallet gate for safe goods transfer
- Full handrail and edge protection system
This allowed Truflo to effectively double usable storage space within the same footprint.
2. Integrated Shelving Across Levels
Both levels of the mezzanine were configured with:
- Multiple timber shelf levels per bay
- Open aisle and access zones for efficient picking
- Mesh backing on exposed edges for safety
This created a highly organised, easy-to-navigate storage environment for smaller components.
3. Selective Pallet Racking
To support bulk storage, Storeplan installed:
- Single and double-sided pallet racking runs
- Up to 6000mm high systems
- Adjustable beam levels for flexibility
- Integrated rack protection and SWL signage
This ensured safe and efficient storage for larger items and palletised goods.
4. Workbench & Picking Stations
Dedicated workbench areas were included to support day-to-day operations:
- Longspan workbenches with durable MDF tops
- Louvre panel systems with bin storage
- Structured zones for assembly, sorting, and packing
This improved workflow efficiency and reduced handling time across the warehouse.
5. Safe Access & Workflow Integration
A custom stair system with landing platform was installed, providing:
- Safe and compliant access between levels
- Smooth transition between picking and storage zones
- Clear separation of operational areas
The Outcome
The final result is a fully integrated warehouse fit-out that delivers:
- Increased storage capacity without expanding footprint
- Clear, structured storage zones for improved organisation
- Safer operations with compliant access and protection systems
- Faster picking and handling efficiency
- A scalable layout ready for future growth
Truflo now operates from a space that is not only functional, but strategically designed to support long-term business performance.
Ready to optimise your space?
If you are planning a new warehouse, relocating, or simply outgrowing your current setup, we can help you unlock more capacity from the space you already have.
Get in touch with Storeplan to discuss how a planning-led fit-out can transform your warehouse into a safer, more efficient, and future-ready operation.
