Faced with limited floor space and rising inventory, Hira Industries extended racking and storage heights and introduced Aisle Master articulated forklifts to gain capacity, improve flow and maintain safety without enlarging the building footprint.
Combilift and local dealer Kanoo Machinery UAE handled site survey, operational analysis and a tailored warehouse design to optimise material flow within the existing footprint.
A fleet of four Aisle Master articulated forklifts enabled narrow-aisle, high-level picking while adding camera systems, laser guidance and lift-height preselection to improve speed and safety.
The redesign supports continuous movement between zones and handles both raw materials and finished goods, helping Hira meet production and delivery demands without expanding the site.
# The challenge: limited floor space as volumes grew
Hira Industries expanded across the GCC, India, Southeast Asia and the United States. As inventory volumes rose, the company outgrew its previous warehouse infrastructure. The facility had to accommodate more pallets and higher throughput while staying inside the same building footprint.
# The solution: build up, not out
Hira moved to a vertical storage strategy. The racking system extends to heights of up to 15 metres and material is stored up to 18 metres. This approach focused on using available cubic metres rather than adding land or building area.
Combilift and Kanoo Machinery UAE performed a site survey and operational analysis, then the Combilift warehouse design team developed an optimised layout tailored to Hira's workflows. The design aimed to improve accessibility and material flow while maximising storage density.
# Materials handling choice: Aisle Master articulated forklifts
Hira selected the articulated Aisle Master for one main reason: narrow-aisle manoeuvrability together with high-lift capability. A fleet of four Aisle Masters was deployed to operate within the new high-density layout.
Key equipment features used in the operation:
These elements reduce operator strain and improve accuracy when placing and retrieving loads at elevated positions.
# Results: capacity and operational improvements
Beyond raw capacity gains, the new layout improved material flow. The design supports continuous movement between zones and facilitates handling of both raw materials and finished goods, which helps Hira meet production schedules and customer delivery timelines.
# Safety and efficiency trade-offs addressed
Working at heights introduces safety and productivity trade-offs. Hira mitigated those by selecting forklifts with built-in safety and assistance technologies. The ability to preset lift heights and operate with enhanced visibility shortened handling cycles and reduced the risk of placement errors.
# Operational impact and strategic value
The project converted a space constraint into a scalable logistics solution. By combining vertical racking, a purpose-built layout and handling equipment suited for narrow aisles and high lifts, Hira increased density and kept workflow efficiency. Operations director Umesh Unni framed the move as a way to grow within the existing footprint while maintaining control over the operation.
# What this means for similar warehouses
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