Discover how stow helped Westons Cider double warehousing capacity with the Atlas® 1D pallet shuttle, delivering high-density storage, faster retrieval, and safer operations.
About the customer
When a fourth-generation, family-owned cider maker decides to invest in its future, the storage solution has to match that ambition. Westons Cider turned to stow to power the heart of its new distribution center in Ledbury, choosing the stow Atlas® 1D pallet shuttle system to double warehousing capacity and streamline deliveries across domestic and export markets.
The result is a semi-automated facility built for growth, efficiency, and safety, without compromise.
The challenge:
more capacity, faster flow, greater resilience
Westons Cider needed room to grow. Rising demand across its markets called for a distribution center that could handle significantly more volume while keeping operations efficient and responsible.
The goals were clear:
- Roughly double existing warehousing capacity
- Add more than 3,000 pallet spaces within a new 43,000 sq ft facility
- Speed up stock retrieval and improve inventory accuracy
- Strengthen safety for warehouse staff
- Support long-term growth as part of a £3.5m investment
Traditional static racking, with its many access aisles, would have wasted valuable floor space. Westons needed a smarter approach to storage density, one that delivered high capacity without sacrificing reliable, day-to-day performance.
The solution: the stow Atlas® 1D pallet shuttle system
stow delivered a semi-automated shuttle racking system built around the stow Atlas® 1D. This high-density storage and retrieval solution transports pallets autonomously within deep-lane racking channels, removing the need for multiple forklift aisles and unlocking far more usable space in the same footprint.
Here is how it works in practice. Forklift operators simply place pallets at the front of a channel. From there, the shuttle handles all internal transport, moving goods within the lane with precision and consistency. Fewer forklift movements inside the racking means less collision risk, better product protection, and a calmer, safer working environment.
Because the system is semi-automated, it strikes a practical balance. Westons gains the efficiency and density of automated pallet handling while keeping operations intuitive and easy to run. Controlled via a robust RF remote, the shuttle requires minimal training and no complex IT infrastructure to get started.
Key strengths of the solution for Westons:
High-density storage
It eliminates unnecessary aisles and maximizes pallet positions.
Faster inbound and outbound flows
Thanks to consistent, semi-automated pallet movements.
Reduced product damage
Accomplished by limiting forklift traffic inside the racking.
The results: performance, accuracy, and safety in one system
The new distribution center gives Westons the capacity and resilience it set out to achieve. By pairing high-density racking with the stow Atlas® 1D, the facility now supports more than 3,000 additional pallet spaces and roughly doubles previous warehousing capacity.
The operational gains are just as important as the added volume:
- Improved operational performance across storage and dispatch
- Faster stock retrieval, keeping goods moving to customers efficiently
- Improved inventory accuracy, supporting confident decision-making
- Enhanced safety for warehouse staff, with fewer forklift movements inside the racking
Alongside the shuttle system, Westons has transitioned more than 80% of its forklift fleet to electric and adopted route-planning software, reinforcing a commitment to operating both efficiently and responsibly.
As Phil Haskew, head of logistics at Westons Cider, put it: “This investment strengthens the foundations of our business for the long term. The new distribution centre gives us the capacity and resilience to support future growth while continuing to operate efficiently and responsibly. As a fourth-generation, family-owned company, we’re proud to keep investing in Herefordshire, in our infrastructure, our people and the community that has supported us for generations.”
Conclusion
For Westons Cider, the outcome is a distribution center that delivers more capacity, faster flow, and a safer workplace, all backed by stow’s engineering expertise and reliable support.
Looking to unlock more capacity from your existing footprint? Speak with a stow expert to design a high-density storage solution built around your operation.