WayhomartFlat-pack shelving: tiers, frames, nesting
There are three layers of volume reduction — knock down, share, nest. Used together they change container loading; used carelessly they tie two SKUs to one design.
Challenge
Welded shelving ships air; knock-down alone removes part of the volume, but tiers and side frames still occupy their own space, and two similar SKUs were developed separately — two sets of fixtures and two carton specifications.
What we did
Removable tiers reduce height, two SKUs share one side frame so fixtures and cartons are shared, and packs nest inside the carton; the load path is kept unchanged and joints are located by locks with tool-free assembly.
Result
- Flat carton with a large height reduction
- Two SKUs share a side frame, and fixtures with carton specifications
- Nesting inside the carton raises packing density
What this file records
A configuration file, not a client story. Client identities and commercial figures are not published; no number is given where none was measured.
Three layers, three trade-offs
| Layer | Method | What you gain | What it costs |
|---|---|---|---|
| Knock down | Tiers separate from uprights | Height drops | More joints; rigidity depends on locks |
| Share | Two SKUs use one side frame | Shared fixtures and cartons | The two designs are tied together |
| Nest | Packs nest in the carton | Density rises | Carton must be redesigned for nesting depth |
The first layer alone usually captures part of the gain. Only all three together produce a visible loading difference — and the third requires a new carton specification, not a reused one.
What a shared side frame implies
Sharing one side frame fixes width, height and joint positions for both SKUs. The benefit is shared fixtures, packaging and material planning; the cost is that changing one model changes both, and differentiation has to live in tiers, accessories and colour.
This is a decision for development, not something to discover after both models are finished.
Two preconditions for nesting
- The shape allows it. Tapered or open structures nest; straight-sided and boxy ones do not.
- Protection is not reduced. Nesting changes load points, so drop and stacking tests must be redone rather than inherited.
The second is the most frequently skipped and the most likely to appear as damage on arrival.
Verification list
- Push the top tier under load; joints should show no perceptible movement.
- Swap side frames between the two SKUs; tiers should still locate.
- Re-run drop and stacking tests on the new carton.
- Itemise carton marking and packing list per SKU.
When it is not worth it
- Sales volumes differ sharply, so the shared design lets the smaller SKU constrain the larger one.
- The market demands fast design changes; a shared frame slows them down.
- Volume does not yet amortise the structural work — start with knock-down only.
Where to go next
- The arithmetic: KD vs welded wire racks.
- Five methods compared: nested and flat-pack design.
- Shelving range: shelving and storage racks.
- Two drawings to evaluate for sharing: contact us.
Related product ranges
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