Streamlining Logistics, Charging Efficiency, and Safety in a High-Throughput E-commerce Distribution Center
Streamlining Logistics, Charging Efficiency, and Safety in a High-Throughput E-commerce Distribution Center
Facility Overview
A large, high-volume e-commerce distribution center operating 24/7 was experiencing growing operational strain as order volume increased. The facility relied on a dense mix of forklifts, pallet jacks, mobile order pickers, temporary packing stations, and floor-cleaning equipment—each dependent on reliable power and charging infrastructure.
As throughput increased, so did congestion, safety incidents, and maintenance costs. Power cords and charging cables became a hidden bottleneck, impacting safety, uptime, and overall warehouse efficiency.
To address these challenges, the facility partnered with KH Industries, a manufacturer of heavy-duty industrial cord reels and power solutions, to design and deploy a safer, more efficient power access strategy across critical warehouse zones
The Operational Challenge
Safety and Compliance Risks in High-Traffic ZonesTrailing power cords created serious trip hazards in active forklift lanes and pedestrian walkways. Temporary workstations, barcode scanners, and floor-cleaning equipment often required floor-level power connections, increasing the likelihood of:
01
Forklift/cord entanglement
02
Slip, trip, and fall incidents
03
OSHA walking-working surface compliance concerns
Safety incidents were not isolated—they were recurring and costly.
Mobile equipment charging was handled opportunistically rather than systematically.
Operators frequently encountered:
- Cables tangled or lying across charging areas
- Delays connecting or disconnecting equipment
- Damaged charging connectors from being run over
These inefficiencies translated directly into non-productive labor time and reduced equipment availability.
Excessive Cable Damage and MRO Spend
Standard power cords and charging cables were not designed for continuous exposure to heavy industrial traffic.
As a result, the facility faced:
- Frequent cable and connector replacement
- Unplanned downtime for forklifts and pallet jacks
- Escalating annual MRO costs tied directly to damaged electrical assets
Seasonal Workflow Bottlenecks
During peak seasons (notably Q4), temporary packing stations were deployed rapidly.
Power access was improvised, leading to:
- Cable clutter around packing lines
- Slower movement of goods
- Poor visibility and limited access for MRO inspections
The Solution: Engineering a Centralized, Safer Power Access Strategy
KH Industries’ engineering and technical sales teams worked directly with the facility’s operations, safety, and maintenance stakeholders to evaluate traffic patterns, charging loads, amperage requirements, and mounting constraints. The result was a tailored reel-based power distribution solution focused on safety, durability, and speed of operation.
Overhead Mounted Cord Reels for Packing and MRO Stations
Heavy-duty, ceiling-mounted KH Industries RTB Series industrial cord reels were installed above primary packing lines and temporary workstations.
Key benefits included:
- Eliminated floor-level power cords in high-traffic areas
- Faster setup and teardown of seasonal workstations
- Improved compliance with OSHA walking-working surface standards
- Immediate access to power without obstructing material flow
Organized Forklift and Pallet Jack “Charging Corrals”
KH Industries recommended high-amperage industrial retractable cord reels specifically rated for battery charging applications.
Each charging position was equipped with:
- A dedicated overhead ree
- Controlled cable payout length
- Automatic retraction after use
Operational impact:
- Cables were never left on the floor
- Charging connections became faster and more intuitive
- Charging connectors were protected from crushing damage
Quantifiable Results the Customer Could See
The deployment of KH Industries industrial cord delivered measurable improvements across safety, efficiency, and cost control.
Safety and Compliance
- Safety incidents reduced from 8–10 per quarter to zero
- Significant reduction of cable-related trip hazards
- Improved OSHA compliance confidence across warehouse aisles
Operational Efficiency
- Charging station connection time reduced significantly by eliminating manual cable handling
- Faster forklift turnaround improved equipment availability during peak shifts
- Seasonal packing stations deployed with minimal disruption
Asset Protection and MRO Savings
- Annual cable and connector replacement costs reduced from approximately $15,000 to $2,000
- ~87% reduction in electrical MRO spend related to damaged cords
- Extended service life of charging infrastructure
Throughput and Workflow
- Packing-area bottlenecks caused by cable clutter were eliminated
- Hourly order fulfillment rates increased during peak demand periods
- Hourly order fulfillment rates increased during peak demand periods drops
— WHY KH INDUSTRIES
This project succeeded not simply because of the product, but because of the engineering support behind it.
KH Industries’ technical sales team:
- Assessed real-world warehouse traffic and duty cycles
- Recommended reel configurations based on amperage, cable length, and mounting height
- Ensured durability for continuous 24/7 operation
- Supported long-term scalability as throughput increases
By replacing unmanaged floor-level power cords with strategically placed industrial retractable cord reels, this e-commerce distribution center transformed a persistent safety and efficiency liability into a competitive operational advantage.
The result was a safer facility, faster workflows, reduced maintenance costs, and improved uptime—critical outcomes for any high-throughput logistics operation. KH Industries industrial cord reels proved to be a foundational infrastructure upgrade, not just an accessory—delivering long-term value in one of the most demanding warehouse environments.
