A Sammons Warehouse Solutions Company

Warehouse Design Services

Custom layout design, technology integration, and engineering that transforms your distribution center into a high-performance operation built for your SKUs, your workflows, and your growth targets.

Design built on engineering — not guesswork

PWD was founded by mechanical engineers and every design engagement is led by engineers. We blend warehouse consulting expertise with precision engineering to produce designs that are validated against your real data before a single rack is ordered.

Custom Warehouse Layout Design & Engineering

Precision Warehouse Design provides full-service warehouse design and engineering for new construction, facility retrofits, and major operational upgrades. Based in the Dallas-Fort Worth Metroplex, our design teams serve clients nationwide across e-commerce, retail, 3PL, pharmaceutical, cold storage, and industrial sectors.

Our warehouse design process is data-driven and engineering-led. We begin with your throughput requirements, SKU profile, labor model, and growth projections — then design a facility that delivers maximum efficiency per square foot, seamless material flow, and a clear path to automation as your business scales.

Every PWD design engagement includes a fully documented set of engineering drawings and specifications. Our team will then coordinate the installation for end-to-end execution.

FasTrak Design Services — Warehouse Design in Days

For businesses that cannot wait weeks for a design solution, PWD’s FasTrak Design Services delivers precise, implementation-ready warehouse layouts in an accelerated timeframe — often within days of engagement kickoff. FasTrak covers needs assessment, layout design, technology recommendations, and bid specification, all on an accelerated schedule. Ideal for urgent retrofits, expansion projects, and time-sensitive procurements.

Our Warehouse Design Services

PWD designs every element of a high-performance distribution center — from the floor plan and racking layout to automation integration and controls infrastructure.

Service
What it delivers
Custom Layout Design
Floor plans engineered for your specific SKU mix, order profile, and throughput targets. We design for optimal material flow, labor efficiency, and future scalability — for both new builds and retrofits.
Technology Integration Design
End-to-end design of conveyor systems, sortation, AS/RS, goods-to-person solutions, pick-to-light, print-and-apply, AGVs, and AMRs. Every technology element is designed as a cohesive, connected system.
Space Utilization Design
Cubic capacity analysis and racking design that matches storage technology to product velocity, weight, and cube — maximizing throughput per square foot and reducing put-away and retrieval time.
Controls & Panel Design
Intelligent control system design that connects and orchestrates every layer of automation — from conveyor controls to WMS/WCS integration and SCADA monitoring.
Ergonomics & Safety Design
Worker-centered design that reduces repetitive strain injury risk, improves pick productivity, and ensures compliance with OSHA, ANSI, and NFPA standards.
Relocation & Expansion Design
Full facility move and expansion planning — sequencing the transition to protect your supply chain while delivering a more efficient, scalable layout on the other side.

Why Choose PWD for Warehouse Design?

Engineering-led, not vendor-led

PWD designs around your operational requirements — not around a product catalog. Because we are systems integrators and not tied to a single equipment manufacturer, we specify the right technology for your operation, whether that means Hytrol, Interroll, Allen-Bradley, or any other best-in-class manufacturer.

Simulation before commitment

Every significant design is validated through simulation modeling before you commit to a layout. We model throughput, congestion points, labor demand, and failure modes — so you can review a data-validated design, not just a drawing.

Design + install under one roof

PWD’s design engineers and installation crews work from the same drawings. When your design moves to installation, there is no translation loss, no finger-pointing between design and field, and no surprises on site.

Virtual and on-site design capability

PWD provides both virtual and on-site design and engineering services. We travel nationwide and have completed projects ranging from small regional DCs to large-scale automated fulfillment centers.

Our Warehouse Design Process

Industries We Design For

  • E-commerce and direct-to-consumer fulfillment

  • Retail and omnichannel distribution

  • Third-party logistics (3PL)

  • Food and beverage — ambient, refrigerated, and frozen

  • Pharmaceutical, medical device, and healthcare

  • Industrial manufacturing, MRO, and heavy distribution

  • Cold storage and temperature-controlled environments

Technologies We Design With

PWD’s design engineers are experienced with the full spectrum of material handling and warehouse automation technology, including:

  • Conveyor and sortation systems (Hytrol, Interroll, and others)

  • Automated storage and retrieval systems (AS/RS) — unit load, mini-load, and shuttle

  • Goods-to-person and goods-to-robot solutions

  • Autonomous mobile robots (AMRs) and automated guided vehicles (AGVs)

  • Pick-to-light and put-to-light systems

  • Print-and-apply and automated labeling

  • Warehouse management systems (WMS) and warehouse control systems (WCS)

  • SCADA monitoring and controls infrastructure

  • Pallet racking, shelving, and high-density storage systems

Frequently Asked Questions

What is the difference between warehouse consulting and warehouse design?

Warehouse consulting analyzes your current operation and produces a strategic plan — answering what you should do and why. Warehouse design takes that plan and produces engineering drawings and specifications that answer exactly how to build it. PWD offers both, and the two services are designed to connect seamlessly.

How long does a warehouse design engagement take?

A standard custom layout design engagement typically takes four to eight weeks from discovery through final drawings. FasTrak engagements can deliver an initial design within days for urgent situations. Large-scale, highly automated projects with simulation validation may take ten to sixteen weeks.

Do I need to complete a consulting engagement before starting a design?

Not necessarily. If you have clear operational data, a defined budget, and an existing facility assessment, PWD can begin a design engagement directly. However, clients who complete a consulting engagement first typically arrive at a better design faster — and with fewer costly revisions.

Do you work on both new construction and retrofit projects?

Yes. PWD designs for new construction, facility retrofits, and expansions. We partner with general contractors and architects on ground-up builds and work directly with businesses upgrading an existing operation. Note that retrofits often require more detailed design work due to existing structural and utility constraints.

Modern warehouse interior

Ready to Design a Warehouse That Performs?

Connect with a PWD design engineer for a free initial consultation. We will review your current operation, discuss your growth goals, and give you a clear picture of what a custom warehouse design engagement would deliver for your business.

Contact Precision Warehouse Design at precisionwarehousedesign.com or reach our North Dallas headquarters directly to start your design project.