Thistle Systems

15/01/2026

Why Automated Pallet Storage Makes Sense in Cold Stores

The economics of cold storage leave very little room for inefficiency.
- Energy costs are high.
- Labour is harder to retain.
- And every unnecessary movement costs money.

That’s why automated pallet storage is increasingly being used in chilled and frozen environments. By storing pallets at high density and automating movements inside the racking, cold stores can:
• Maximise cubic utilisation, reducing the volume that needs to be chilled or frozen
• Cut energy consumption, by minimising air space and door openings
• Reduce labour exposure to harsh, sub-zero environments
• Improve throughput predictability, even during peak demand
• Operate more safely, with fewer forklifts and less manual handling

The biggest gains often come from something simple.
Storing more pallets in less refrigerated space.

Automation doesn’t just improve performance in cold stores.
It fundamentally changes the cost model.

We’ve broken this down in more detail, including where automation delivers the strongest ROI and when it makes sense to adopt it.

👉 Read the full blog here:
https://thistlesystems.co.uk/automated-cold-storage-warehouses/

14/01/2026

Discover How Brightpick Robotic Order Picking Is Redefining 3PL & Ecommerce Fulfilment

Speed, accuracy, and labour availability are now make-or-break for 3PLs and ecommerce operators.

In a recent project for a major 3PL, Brightpick’s robotic order picking transformed a fulfilment operation delivering incredible results:
✅ 75% reduction in picking and replenishment labour
✅ 200 picks per hour today, with the ability to scale to 500+ picks per hour without adding labour
✅ Automated storage, retrieval, and putaway in a single integrated solution
✅ Double the storage density within the same footprint

The biggest win? Throughput increased while labour dependency dropped — giving the operation the consistency, accuracy and flexibility to scale for peak demand without increasing headcount.

This is what modern Ecommerce fulfilment looks like when automation is designed around real operational data.

👉 Read the full case study here:
https://thistlesystems.co.uk/robotic-order-picking-3pl-ecommerce-fulfilment/

12/01/2026

Why Shuttle Racking Works So Well

Most warehouse constraints aren’t caused by a lack of floor space. They’re caused by how that space is used.

Shuttle racking solves this by attacking the problem at its core. Density.

If your operation stores large volumes of the same SKU, traditional racking wastes space on aisles and forklift travel. Shuttle systems remove those aisles and replace movement with structure.

The result is dramatically higher storage density within the same footprint.

But density is only part of the story.

By reducing forklift travel, shuttle racking also:
• Improves throughput
• Simplifies traffic flow
• Reduces handling time and risk
• Creates a calmer, safer warehouse environment

It’s especially effective where pallet flows are predictable and repeatable, and where the priority is storing more, moving less, and doing both reliably.

Good warehouse design isn’t about complexity.
It’s about aligning the solution with the physics of the operation.

Shuttle racking does exactly that.

08/01/2026

How To Store 140 IBCs In Just 55m² of Floor Space.

When space is tight and compliance is non-negotiable, the fantastic Thistle Systems design team has to demonstrate its expertise and experience in IBS storage solutions.

In this project, we delivered a purpose-built High Density IBC storage solution with integrated drip trays that allowed our client to safely and compliantly store 140 IBCs in just 55 square metres.
No Stacking. No compromises. No wasted space

👉 Read the full case study here:
https://thistlesystems.co.uk/casestudies/ibc-storage-with-drip-trays/

07/01/2026

Happy New Year from Thistle Systems 🎉

We’re kicking off 2026 with the commissioning of our latest Autocube automated warehouse project for Mega Fortris.

This project is another great example of how intelligent pallet automation can deliver high-density storage, predictable throughput, and long-term scalability for growing operations.

A big thank you to the teams at Mega Fortris and everyone involved in delivering another successful project.

Here’s to a year of smarter warehouses, better performance, and clients for life.

06/01/2026

How Much Does a Mezzanine Floor Really Cost?

If you’re running out of space, a mezzanine floor can look like the obvious answer. But the headline price rarely tells the whole story.

Costs can vary dramatically depending on load requirements, layout, fire protection, access, building regulations, and how the space will actually be used.

Get it right, and a mezzanine can unlock huge value.
Get it wrong, and it becomes an expensive compromise.

We’ve broken down the real factors that influence mezzanine floor costs, what you should budget for, and how to avoid costly mistakes in our latest blog.

👉 Read it before you start planning.
https://thistlesystems.co.uk/mezzanine-floor-costs/

05/01/2026

Why you should Automate in 2026

Automation isn’t about replacing people - it’s about removing bottlenecks, maximising efficiency, and scaling operations easily and smoothly.

Warehouse Automation delivers real, measurable results for businesses who are looking to survive and thrive, including:
✅Reduced Labour Costs and dependency
✅Increased Pick Speed to reflect rising demand
✅Increased Throughput without additional floor space
✅Minimised Risk of Product Damage
✅Improved Safety for your workforce

More UK companies are exploring the adoption of warehouse automation to gain a real competitive advantage.

To see why you should be exploring warehouse automation in 2026 visit https://thistlesystems.co.uk/warehouse-automation-uk/



01/12/2025

📦 How Much More Could You Store?

The biggest driver for most businesses exploring automated pallet storage is the massive increase in capacity it delivers. We’re talking exponential gains in usable space, often without expanding your footprint.

But once that’s realised, the real opportunity for transformational change follows:
⚡ Faster throughput
🦺 Improved safety
💰 Lower operating and energy costs

It’s all part of a compelling ROI story that’s transforming warehouses across the UK.

👉 Discover how much more capacity your site could unlock:
https://thistlesystems.co.uk/how-much-additional-capacity-will-automated-racking-systems-provide/

21/11/2025

As well as our automated storage solutions, we continue to provide key dynamic and traditional storage systems to major clients. This includes mezzanines and pick towers that work either as standalone installations or as supporting infrastructure for automated projects.

Mezzanine floors are often viewed as one of the most effective ways to create additional space without extending your building or renting new premises. However, the term is frequently misused, and many companies end up paying for an over-engineered structure they do not actually need.

So what is the real difference between a mezzanine floor and a picking tower?

We break it down clearly in our latest blog.
👉

What is a Mezzanine Floor? Mezzanine Floors are a great solution to create additional capacity when you have available height. Find out more.

20/11/2025

How Much Additional Capacity Will Automated Pallet Storage Provide Me?

Automated pallet systems allow you to increase storage capacity, maximise every cubic metre, and regain control of your inventory. The results can be dramatic - more capacity, lower costs, and greater operational stability.

We have broken down the numbers in our latest blog - including how much additional capacity automated racking can deliver and where the biggest gains come from.

👉 Read the full article: https://thistlesystems.co.uk/how-much-additional-capacity-will-automated-racking-systems-provide/

19/11/2025

🌙 When your warehouse never sleeps… your productivity doesn’t either.

Many fulfilment operations still rely on one or two shifts to pick, pack, and replenish.
That means packers often start the day waiting on stock… and pickers slow down near the end of theirs - leaving valuable hours (and efficiency) on the table.

But imagine walking in each morning to find your Brightpick robots have been hard at work overnight:
🤖 Picking orders with precision
📦 Placing them neatly in the packing buffer
🚚 Ready to ship first thing - no delays, no downtime

With 24/7 autonomous operations, you can:
✅ Ship faster and improve customer satisfaction
✅ Reduce dependency on labour and shift patterns
✅ Maximise warehouse throughput and ROI

The best part? They do it quietly… and even in the dark. Watch them in action 👇