UNITED KINGDOM / AGILITYPR.NEWS / April 16, 2026 / Pallet Truck Shop, the UK’s largest supplier of pallet and sack trucks, is warning of a growing mismatch between warehouse design and operational reality as rapid shifts in ecommerce, returns volumes and SKU complexity push facilities beyond their original purpose.

Many warehouses currently in use across the UK were designed for simpler, more predictable supply chains. Bulk storage, linear flows and limited product variation were once the norm. Today, however, operators are dealing with fragmented order profiles, higher return rates and an ever-expanding range of SKUs - all within the same physical footprint.

According to Pallet Truck Shop, this evolution is placing strain on layouts that were never intended to support such dynamic activity. Picking zones are expanding into storage areas, returns processing is being squeezed into already tight spaces, and pallet movements are becoming more frequent and less predictable.

Phil Chesworth, Managing Director at Pallet Truck Shop, said the shift has been gradual but profound. “Warehouses are being pushed beyond what they were designed to handle,” he explained. “The rise of ecommerce and returns has changed how goods flow through a site. Instead of straightforward in-and-out movements, there are now multiple touchpoints, more frequent handling and constant reorganisation.”

Chesworth added that while businesses have adapted processes, they have not always adapted the equipment supporting them. “One of the biggest issues we see is a mismatch between the environment and the tools being used,” he said. “Equipment that was suitable for bulk storage and wide aisles can become inefficient or even problematic in tighter, more complex layouts.”

The company notes that outdated or oversized pallet trucks, stackers and table trucks can restrict movement, create bottlenecks and increase the risk of minor collisions or handling errors. In contrast, equipment designed for manoeuvrability and precision can help operators navigate evolving layouts more effectively.

“As operations evolve, equipment needs to evolve with them,” Chesworth concluded. “Warehouses don’t always get rebuilt overnight, but the way goods are handled can be improved immediately with the right approach. Recognising that mismatch is the first step towards fixing it.”

To find out more about Pallet Truck Shop, visit: www.pallettruckshop.co.uk.