Stacked Farm

As a rapidly expanding business, Stacked Farm’s requirements were evolving almost daily. At the time of engagement, they were setting up a new site and still refining how their storage would integrate with production. The main challenge was to create a system that met strict hygiene and food-safety standards, while also providing flexibility for a business model that was still taking shape.

Initially, Stacked Farm didn’t have an established process for handling and storing their final product in a sterile way. It was new territory for both their team and ours, as this project required combining warehouse racking design with food-production compliance. To make it work, we needed to understand their operations in detail, including the specific ISO standards they were working toward, so we could design a compliant and practical solution from the ground up.

Without a fit-for-purpose racking system, Stacked Farm risked inefficiencies in workflow and potential non-compliance with health and food-production requirements. Their initial layout didn’t fully account for how different zones needed to be separated, what materials were appropriate for a hygienic environment, or how to maintain temperature-controlled storage without compromising accessibility. As their production volumes increased, these limitations would have quickly become bottlenecks in handling both raw and finished goods.

Working from a blank canvas, QLD Storage Systems developed a layout that balanced capacity, compliance, and adaptability. The project centred on selective pallet racking, chosen for its versatility and accessibility across multiple operational zones.

The warehouse was divided into two main environments. The general warehouse served as the base for non-sensitive bulk materials, while the chilled storage rooms provided a sterile, temperature-controlled area for the harvested produce. Both zones used selective pallet racking configured to suit their specific storage and handling requirements.

Because of the high hygiene standards, all racking was hot-dip galvanised. This approach provided the structural strength of steel with a corrosion-resistant surface suitable for food production. It also eliminated the need for stainless steel, which isn’t structurally rated for this type of system. Forklift aisle widths, lift heights, and weight capacities were carefully designed with future growth in mind, allowing the system to evolve alongside the business.

The completed installation gave Stacked Farm a storage system that was both compliant and operationally efficient. The new layout improved storage density, streamlined the flow of materials from growing to dispatch, and ensured every component of the facility met the required hygiene and food-safety standards.

By integrating their raw-material storage, chilled product handling, and distribution areas into a single, well-planned system, Stacked Farm gained the flexibility to expand production without compromising quality or compliance. The racking has since proven adaptable as the business continues to refine and scale its operations.

This project demonstrated how even highly specialised industries such as vertical farming rely on engineered racking solutions to meet strict regulatory and operational demands. QLD Storage Systems continues to support Stacked Farm with ongoing layout refinements and relocation work as their facility evolves.
If your business requires a compliant, high-performance storage solution, QLD Storage Systems can help. We specialise in warehouse racking design for retail and e-commerce, as well as complex environments such as food production and controlled warehousing. Contact our team today to discuss a solution tailored to your business growth and compliance needs.