How to Reduce Product Damage in your Warehouse

In warehouse and manufacturing operations it is inevitable that some products will get broken. If you have been in business a long time you will know that broken products can cost a company thousands of pounds. But there are things you can do to reduce product damage in your warehouse.

Follow the tips below to learn how you can minimize the cost of inventory damage.

Regularly Check Your Pallets

Pallet damage is one of the most common causes of broken goods. Pallets need to be manually checked on a regular basis. Stacked pallets or those on a warehouse floor can collapse entirely if the pallet is faulty. As well as product damage, this can cause serious injury to an employee.

Ensure Pallets are Stacked and Wrapped Correctly

There is an art to stacking pallets and with the slightest oversight, disastrous consequences can occur. The load must always be stacked in a cubed, uniform, and stable manner and the wrapping of pallets must be executed properly whether by hand or by a automated pallet wrap machine.

Always Follow Guidelines for Weight Tolerance

Be aware what weight shelving can tolerate when stacking products or pallets. It is important to know the shelving manufacturer’s recommendations and guidelines for weight and this should be adhered too at all times. Never overload shelves or racks, and use rack weight load notice signs. Overloading racks or racks loaded incorrectly can cause catastrophic accidents which can destroy inventory and seriously injury employees.

Warehouse Lighting

Many accidents happen when warehouses have poor lighting. Bulbs fail and unless you are regularly checking every corner of your warehouse, then accidents are bound to happen. You might find that the main warehouse area has sufficiently visibility, but are all the aisles and corners getting that light? This is when it’s important to check all aisles and corners of your warehouse and if necessary add extra lighting or upgrade the whole lighting in your warehouse. As well as helping to prevent damage, by enhancing visibility in the warehouse can also save energy.

Keep Aisles Clean and Tidy

This again is common sense but it is imperative that all areas of the warehouse are kept clean and tidy at all times. The cleaner and tidier your warehouse is, the less chance there is of products getting damaged. Warehouse managers need to ensure there the warehouse is free of any kind of obstruction at all times.

Use Rack Safety Netting

Rack safety netting stops cartons from falling and loads breaking open. Also anti-collapse mesh safety screens can be use on the back of racks to stop product or items falling. Any product or items that fall from a pallet at a higher level will either be held within the mesh or will fall within the rack minimising the danger of injury.

If your concerned about financial waste through damaged products or need a health and safety policy or plan get in touch. Here at 2h Storage health and safety is paramount. If you have any questions on load notices or need advice on racking safety inspections call our team here at 2h Storage on 01937 585057

Richard Haynes has been in the industrial warehouse industry for many years. You can find him on

Leave a Reply