Introduction
Stellantis is a global leader in car manufacturing, with a stunning portfolio of legendary brands like Maserati, Fiat and Jeep. The multinational wanted to open a new warehouse in Ellesmere Port (UK) near Chester. To do so, they would need to build and design one from scratch. A challenge they entrusted to stow.
Unique storage challenges
Stellantis was formed in 2021 from the merger between Fiat Chrysler Automobiles (FCA) and Groupe PSA. With a diverse portfolio of 14 iconic brands, including Maserati, Fiat, Peugeot, Citroën, Jeep, and Opel, Stellantis is the world’s fifth-largest automaker by volume. The group operates more than 50 manufacturing facilities in 24 countries, serving over 130 markets globally. Stellantis is headquartered in Hoofddorp, the Netherlands, with key regional offices and R&D hubs spread across Europe, North America and Asia.
To support its UK aftersales operations, Stellantis opened a brand-new 60,000 m² Parts Distribution Centre (PDC) in Ellesmere Port in 2025, equivalent to nine football pitches. With over 140.000 parts stored up to 14 meters high and servicing 10 vehicle brands, the logistical demands were considerable.
Car parts vary widely in size, shape and handling needs. From small electronic components to exhaust pipes, every item required a precise, fit-for-purpose storage solution. Stellantis needed not only diversity in racking types, but also seamless integration, top performance and scalable capacity.
Three core solutions. One expert supplier.
To meet the client’s highly specific storage requirements, stow designed a fully customized racking system for the new warehouse. This would allow storage of standard pallets, baskets of two varying dimensions, boxes, vertical storage and direct storage of elements without packaging.
- Pallet racking across 34.000 m², featuring two- and three-legged frames for maximum load-bearing versatility. Mesh decks, backstops and anti-fall fences increase safety and adaptability. These systems handle the heaviest and most frequently moved stock and are designed for fast, safe forklift access.
- Shelving spanning 8.000 m² over two levels, making optimal use of vertical space for smaller items. Adjustable shelves and dividers create flexibility for different box sizes and categories. This structure supports high-density picking and quick replenishment.
- Cantilever racking, ideal for long, heavy goods such as bumpers, pipework and structural elements. These systems offer unobstructed access, reducing handling time and damage risk. Their modularity allows for simple reconfiguration as needs evolve.
A wide range of accessories, including dividers, mesh decks, anti-fall fences, gratings, backstops, vertical rods with rubber protection and more, ensure that every storage scenario is covered. This proactive and highly tailored approach makes stow not just a supplier, but a strategic partner.
Facts & Figures
60.000 m2
warehouse
4.331.995 kg
of steel
34.000 m2 of
pallet racking
8.000 m2
of shelving
The result
What makes this project stand out? All three fundamental stow solutions are seamlessly installed together in a single facility, tailored precisely to the client’s requirements. A unique feat that reflects the strength and breadth of stow’s product portfolio and its ability to deliver a one-stop solution for complex logistics. These three systems integrated in one coherent design is no coincidence. With decades of engineering expertise and in-house development across all racking types, stow is uniquely positioned to deliver such complexity from a single source. This end-to-end capability, combined with a proven track record for global brands, sets stow apart as a powerful logistics partner.
Cross-border collaborationas a driving force
From initial request to design and implementation, this project spanned a two-year period. Pallet and cantilever racking were installed during a 200-day period, shelving during an additional 110-day period. This project wasn’t simply a technical challenge, it was a logistical one as well due to its international character. “We’ve got project managers and sales in France, production in Belgium and, of course, construction at the client’s site in the UK”, says Hadi Diab, project manager at stow.
“Every country has its own habits. Thanks to our global expertise and strong local presence, we were able to overcome logistical and regulatory challenges to deliver a reliable, high-performance solution for Stellantis.”
Maximum storage efficiency, built for the future
The Ellesmere Port warehouse has been fully optimized for storage, both vertically and horizontally, maximizing capacity and efficiency. Clear zoning and logical layout planning have resulted in better organization, smoother workflows and increased safety on the floor. In total, over 4.331.995 kg of steel were used to build the racking systems, a powerful physical expression of the project’s scale and strength.
Diane Miller, Stellantis UK Parts Distribution Centre Manager, said: “The relocation of our parts operation to Ellesmere Port has been a huge effort by everyone involved, but now ensures a more efficient process by bringing all Stellantis brands under one roof. Thanks to the more central location afforded by Ellesmere Port, we also benefit from better transport links for distribution to our 19 regional hubs across the UK and Ireland.”
The warehouse isn’t just efficient, it’s future-proof. By integrating green technologies and building performance into every aspect of the design, the PDC proves that operational excellence and sustainability can go hand in hand. The combination of space-efficient storage and smart energy management makes this warehouse a benchmark for sustainable distribution in the automotive sector.
Sustainability that works
The Stellantis PDC also sets new standards for sustainability: it is the first UK warehouse to have achieved the BREEAM “Outstanding” certification, the world’s leading sustainability benchmark for buildings and infrastructure.
This achievement is the result of several integrated measures: a 7.000-litre rainwater harvesting system, wastewater retention ponds that filter water before release into the Manchester Ship Canal, and the use of LED lighting throughout the facility. The employee car park also features 32 EV charging points to support electrification.
Another key initiative is Stellantis’ global use of the OTIF (On Time in Full) logistics system, which maximizes the load volume of both inbound and outbound truck deliveries. Since the opening of the Ellesmere Port facility, this system has helped reduce the number of return truck journeys by around 60 per week, a 60% reduction that directly contributes to lower emissions and greater efficiency.
Conclusion: From concept to reality
This project proves that strong partnerships lead to strong outcomes. For Stellantis, stow delivered more than a system, they delivered peace of mind, future readiness and operational strength. Project manager Diab: “The client particularly appreciated our flexibility to adapt to their needs and our problem-solving approach.”
“It’s like solving a complex puzzle where every piece fits perfectly. The client is happy with the result and the efforts that made it possible”, says Diab. Stellantis has a new, professional, clean and future-proof environment that enhances day-to-day operations.
About stow
stow is a leading provider of industrial storage solutions, specializing in racking systems tailored to every sector. With decades of experience and a global presence, stow delivers scalable, high-performance solutions that optimize space, enhance safety, and support operational efficiency.
This case is a testament to stow’s deep expertise in the automotive industry. From decades of collaboration with leading OEMs and suppliers, stow understands the sector’s unique logistics and production dynamics, from short delivery models to the high variability in part dimensions and handling requirements.
