Third-party logistics (3PL) warehousing is truly the engine room of modern supply chains - high velocity, multi-client, SKU-heavy and under relentless pressure to do more with less. It doesn’t matter if you’re managing fulfilment for eCommerce giants or niche B2B operations, the challenges remain the same: space constraints, accuracy demands and scalability expectations.
Thankfully, warehouse mezzanine systems are the ideal antidote to these common issues. Rather than serve as add-ons, they actually maximise unused vertical space, create dedicated zones and support scalable automation, mezzanine in logistics transforms warehouse operations from the ground up (and above it). At Unistor, we’ve helped countless logistics providers transform their warehouses with smart mezzanine design. Here are five practical ‘hacks’ for getting the most out of your mezzanines to take your 3PL facility to the next level.
Hack #1: vertical storage expansion using mezzanines
Vertical expansion is one of the most cost-effective ways to grow your capacity without the disruption and cost of relocating. By integrating mezzanine platforms into your warehouse, you instantly double or even triple usable space within the same footprint.
Unistor mezzanine systems can be designed to suit your racking and automation needs - think pallet racking beneath, pick modules above and clear zones for order staging. Our modular frames support everything from lightweight goods to heavy inventory, with tailored load ratings to match your operational requirements.
Planning your layout with vertical flow in mind also improves movement and pick efficiency, especially when paired with access solutions like lifts or conveyors between levels.
Hack #2: segmentation of storage zones by client or SKU type
In a multi-client warehouse, it pays to keep things in their lane. Using mezzanine levels to divide space by client, SKU velocity, or product type makes it easier to manage accountability, stock accuracy and turnaround times. A dedicated level or quadrant for each client can improve transparency and reduce mix-ups - especially critical in peak periods when pressure and error rates tend to climb.
By physically separating stock zones, industrial mezzanine structures support tighter inventory control. Teams can pick, pack and manage orders without navigating congested floor layouts or cross-client confusion.
Hack #3: streamlining automation integration
Automation is the new standard for competitive 3PL warehousing. Mezzanines make it easier to design warehouses that support both manual and automated systems. No matter if you’re a running conveyor-based sortation, robotic pick stations, or automated packaging lines, mezzanines help bridge your tech stack across multiple levels.
For instance, an upper mezzanine can house lightweight SKUs picked by AMRs (autonomous mobile robots), which then drop products onto conveyor belts feeding packaging lines on the ground floor. By tiering these workflows, you reduce floor congestion and enhance throughput.
A mezzanine in logistics also allows for protected routing of cabling, sensors and system components. This keeps your automation infrastructure safe from damage while remaining easily accessible for maintenance and upgrades.
Hack #4: supporting flexibility for high and low turnover stock
Not all products move at the same speed - so why store them the same way?
Reliable 3PL warehousing should adapt to product velocity. High-turnover goods should live in easily accessible ground-level zones for rapid picking, while slower-moving items can sit on upper mezzanine levels. This kind of layout planning boosts efficiency and makes the best use of your square metre real estate.
With Unistor’s custom-built mezzanine systems, we help operators design layouts that match their SKU profiles and fulfilment logic. Need to keep seasonal stock out of the way until Q4? Allocate it to a raised storage zone. Want to improve pick rates on your bestsellers? Bring them down to eye-level with fast access pathways. It’s all about keeping your inventory in the right place - at the right height.
Hack #5: enabling scalable workflows for seasonal peaks
Warehouse demands don’t stay static - and neither should your infrastructure.
With modular mezzanine systems, 3PLs can expand, contract or reconfigure layouts in response to changing volumes. This is especially useful during peak seasons (think holiday surges or EOFY sales) when temporary expansion is essential but long-term overbuild is a financial burden.
By designing your mezzanine with scalability in mind (such as add-on bays or reconfigurable staircases) you can adapt without major structural upheaval. Mezzanines also serve as excellent temporary processing areas for returns, repackaging, or value-added services like kitting.
Industry use cases: 3PL warehousing success stories
We’ve seen these strategies come to life in some of Australia’s most dynamic logistics environments:
INVENCO - Prestons:
One leading eCommerce 3PL based in Sydney reconfigured its fulfilment centre using mezzanine levels to create dedicated pick zones for high-demand SKUs. By isolating fast-moving inventory on ground level and slower-moving stock above, the business improved pick accuracy and reduced walking time (think hack #4 and hack #1).
Another Melbourne-based 3PL introduced returns processing stations on a raised mezzanine, separating them from outbound and packing areas below. This segregation significantly reduced floor clutter, improved the flow of returned goods, and freed up main-level space for rapid fulfilment tasks.
Coles Ocado
A standout example is Unistor’s work for Coles Ocado, where a custom multi-level mezzanine system was deployed across two fulfilment centres in Sydney and Melbourne. Faced with the challenge of integrating 22,000m² of mezzanine flooring into Cole’s highly automated logistics operations, Unistor delivered a solution that ticked every box:
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Water and wear resistant flooring solution
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Automation compatibility
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Load resilience (supporting over 1200kg for AGV’s )
Installed during the pandemic, the pre-cut panels were assembled on-site like a giant jigsaw - minimising disruption and speeding up deployment. It’s a clear case of mezzanine design solving real challenges for customer fulfilment centers and providing space-maximising solutions.
Why Choose Unistor for 3PL Mezzanine Solutions?
At Unistor, we don’t believe in one-size-fits-all for third-party logistics solutions. With over thirty years of industry experience in Australia, we’re plugged in. Our team works closely with warehouse planners and logistics consultants to design mezzanine systems that match your workflow, automation systems and expansion goals.
We offer:
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Custom load-rated designs for multi-use warehouse
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Seamless integration with WMS and automation hardware
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Compliance with local building codes and OH&S requirements
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Fast-track installation and minimal disruption
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Mezzanine solutions for smarter logistics
Conclusion
We don’t need to tell you that 3PL warehousing is fast-paced, high-stakes and always evolving. But with the right mezzanine strategy, your facility can adapt, expand and deliver - no matter the pressure. Let’s recap the five hacks:
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Vertical Storage Expansion: Maximise capacity without relocation.
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Smart Segmentation: Improve control with client or SKU zoning.
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Automation-Ready Design: Support conveyors, robotics and sortation tech.
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Flexible Inventory Flow: Align layouts with SKU turnover velocity.
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Scalable Infrastructure: Adapt to seasonal peaks without overbuilding.
Whether you’re scaling up, streamlining processes, or future-proofing your warehouse, it’s clear that mezzanine systems are a high-impact, low-disruption investment.Want to see what’s possible in your space? Talk to Unistor today and discover mezzanine solutions that rise to the challenge.
