RETA Mühendislik undertakes the design, production, and installation of industrial shelving systems for manufacturing facilities, sub-industry warehouses, and distribution depots in Düzce under a single responsibility. Established in 1979, the company manufactures its systems in its own production facility in Manisa Muradiye OSB and serves Düzce through its Marmara regional organization.

Production Structure Determining Storage Needs in Düzce

Düzce's industry, with the advantage of being located on the D-100 and TEM axis, has a growing structure where medium and large-scale facilities coexist.

Automotive sub-industry, cable, electrical equipment, and machinery manufacturing are concentrated in the Düzce Organized Industrial Zone and Beyköy line. Most of these facilities feed parts to the main industry in Kocaeli and Sakarya; therefore, the warehouse layout operates depending on the shipment schedule. Line-side stock areas, box-based picking layouts, and intermediate stock zones before shipment are common needs.

Facilities manufacturing weapons, metal processing, and packaging are located on the Düzce Kaynaşlı and Gümüşova line. Here, managing raw materials and finished products under the same roof is common; loads of different weights and dimensions must be resolved within a single layout plan.

Wood products, lumber, and furniture sub-industry facilities on the Çilimli, Gölyaka, and Cumayeri line form the third pillar of the province. Long materials with sensitive surfaces, such as boards, chipboard, and lumber, do not fit the standard pallet logic; the structural design is established based on deflection behavior. In hazelnut processing and food facilities, storage volume fluctuates significantly throughout the year depending on the harvest season.

Rack Safety in Facilities on Fault Lines

Düzce is one of the closest provinces to the epicenter of the 1999 earthquake and is among the regions with the highest spectral acceleration values in the earthquake regulations. Warehouse equipment in facilities within the region is not an element that can be evaluated independently of the building.

A fully loaded pallet rack is a load-bearing structure on its own. In the event of its collapse, beyond the loss of stock, employee safety and keeping indoor escape routes open are at stake. For this reason, upright profiles, anchoring details, vertical and horizontal bracing layouts, and beam connections are dimensioned not only according to vertical load capacity but also according to the seismic parameters of the region.

A system of the same bay capacity that works without problems in a low-risk province may require additional bracing, a different upright profile, or reinforced anchoring in Düzce. Structural calculations are performed separately for each project; quotes are not provided based on catalog capacity.

Prominent Systems in Düzce OSB and Beyköy Line

For line-side feeding and order picking in automotive sub-industry and cable facilities, carton flow rack systems are used. Shelf heights are adjusted according to the operator's reach level, and high-turnover parts are placed on the waist-level band to shorten picking time.

In production facilities in the organized industrial zone and in food and packaging warehouses, pallet rack systems are designed according to pallet size, forklift type, and clear height. Euro pallet 800x1200 mm and industrial pallet 1000x1200 mm dimensions require different bay depths and beam spans; the number of levels is determined according to the ceiling level and sprinkler layout.

In wood products manufacturers and metal processing facilities on the Çilimli and Gölyaka line, long materials such as boards, lumber, profiles, and pipes are stored with cantilever rack systems. Arm length and spacing between arms are determined based on material thickness and deflection behavior, and cushioned when surface contact is required.

In facilities where ceiling height cannot be utilized, mezzanine solutions double or triple the available area. Press and injection molds are managed with mold rack systems, and warehouses with high stock turnover speeds are managed with AS/RS automated storage applications. All system types are available on the rack systems page.

Düzce Warehouse Rack Systems Site Survey and Quotation Process

To get a layout plan and a price quote for your facility in Düzce, contact us via the contact page. Completed applications in different sectors are available on our projects page.

Steps Followed from Site Survey to Commissioning

During the site survey, ground condition and flatness, column axes, clear ceiling height, sprinkler and lighting layout, forklift type used, as well as pallet and load dimensions are recorded. In facilities that feed the main industry, the shipment schedule is also obtained at this stage because both the layout plan and the installation schedule are established according to this rhythm.

After capacity calculations, structural calculations, and technical drawing approval, production is carried out at the facility in Muradiye OSB. Installation is performed on-site by our own teams. Since the warehouse can be worked on by dividing it into stages, installation can be completed without stopping the feeding and shipment flow. Load capacity labels and usage instructions are left upon delivery. The scope also includes expanding existing systems, relocating to another facility, and replacing damaged components.

Frequently Asked Questions (FAQ) About Düzce Rack Systems

Can the seismic resistance of our existing racks be checked on-site?

Yes, it can be checked. Upright profiles, anchoring status, bracing layout, and signs of bending or impact on components are inspected and compared with the current load carried. Based on the results, additional bracing, anchoring renewal, or replacement of damaged components is recommended.

Can you prevent surface scratching in board and lumber storage?

Yes, it can be prevented. Arm surfaces can be cushioned, and the spacing between arms can be narrowed according to the thickness of the material to reduce deflection and surface contact. The handling direction is also included in the plan, so the material does not have to be pulled by sliding it over the arm.

Can installation be done while feeding the main industry?

Yes, it can be done. The warehouse is worked on by dividing it into stages, and the schedule is set according to the shift and shipment hours of the facility. First, the empty section is commissioned, stock is moved gradually, and then installation continues in the vacated area.

Can efficient year-round usage be achieved in hazelnut and food processing warehouses?

Yes, it can be achieved. The layout is planned not only according to the peak occupancy moment but also according to the usage range throughout the year. Sections that reach full capacity during high periods and can turn into consolidation areas during low periods are separated.

What information do we need to prepare for a quote?

Warehouse area and clear ceiling height, pallet or load size and unit weight, target number of storage bays, forklift type used, and existing layout plan, if any, are sufficient. The final quote is generated after the site survey and structural calculations.