Optimizing facility space and product movement by creating 5,500+ pallet positions with a cost-effective and simple striping and signage integration

Based in Secaucus, New Jersey, Bogg Bag has grown into a widely recognized brand known for producing durable, versatile tote bags designed for everyday use. Built from washable, waterproof EVA material, each bag is designed to stand upright, resist tipping, and carry a wide range of items, from beach gear and groceries to daily essentials.

Customers can choose from multiple sizes and colors, with accessories that allow for added organization and customization, making the bags suitable for any environment or task the customer requires.

The Secaucus facility receives the bag materials from overseas, processes it by SKU, and fills retailer and customer orders for shipping. Before the implementation, warehouse staff would place these outbound pallets in a staging area before the dock doors.

The Challenge

Bogg Bag was operating within a bulk storage environment that lacked clear visual structure. While the space had available capacity, inconsistent pallet placement and unclear lane definitions created inefficiencies in daily operations.

Without clear pallet inventory zones - warehouse staff had inconsistent storage and retrieval processes, leading to misplaced inventory, longer travel times, and congestion. 

The goal was not to overhaul and make the operation complex, but to enable inventory and staging positions in a simplistic and cost-efficient manner. 

The Solution

CHC recommended structured striping and overhead signage designed to create a clearly defined and visually controlled storage environment. Each pallet position was laid out and marked with clear yellow caution striping adhered to the warehouse floor, while barcode and SKU information signs were hung over each respective zone - indicating the location of that specific product.

Warehouse Location Signage

• Retroreflective signs with rigid backing
• Angled return for visibility
• Human-readable text paired with barcodes for scanning
• High-contrast design for visibility across long distances

Floor Striping System

• 8,000 linear feet of industrial-grade tape
• 3” wide yellow and black striping
• Engineered for high-traffic durability
• Clearly defines pallet lanes, aisles, and storage zones

 Total Pallet Positions: 5,585

• Small, medium, and large positions for varying pallet order sizes

By introducing floor striping, aisle delineation, and overhead SKU signs, the facility was transformed into a layout that guides operator behavior naturally, without requiring changes to the current labor model or integrating solution equipment.

Each storage lane, aisle, and pallet position was intentionally defined to eliminate errors, misplacements, and improve product movement efficiency overall. 

The Integration

CHC managed the full striping and signage installation, ensuring all elements aligned with the engineered layout and operational goals.

Work included:

• Layout verification and site preparation
• Material staging and coordination
• Installation of signage and drop cable systems
• Precision application of floor striping for lanes and aisles
• Final inspection and system adjustments

To minimize disruption, installation was also completed during evenings and weekends, allowing ops to continue while improvements were made.

This structured approach created a scalable storage environment that reduces congestion, shortens pallet movement, and improves overall flow through the facility. 

CHC has the experience to deliver large-scale automated material handling and storage solutions - but that doesn't mean our capabilities stop there. Each and every project varies greatly, and your goals, budgets, and limitations can be met with the right combination of engineering, innovation, and solution recommendations. This project is an example of how CHC can scale to your specifications and deliver a solution that remains cost-effective yet provides significant efficiency benefits. 

The Result

With clearly defined lanes, consistent visual cues, and structured placement guidelines, the facility now operates with greater discipline and efficiency.

• Faster, more consistent pallet putaway
• Reduced search time and improved retrieval speed
• Fewer misplaced pallets and movement errors
• Improved traffic flow and reduced congestion
• Maximizing floorspace usage efficiently

Most importantly, these improvements were achieved without changing the existing labor model - demonstrating how impactful clear visual controls can be in a bulk storage environment.

Looking for a similar solution?

Not every improvement requires a full system overhaul or advanced solutions. In many cases, the right combination of layout, signage, and clear visual indicators can result in significant gains in efficiency and organization without the high cost.

CHC works with operations teams to identify these “low-hanging-fruit” opportunities and implements solutions that meet your operational trajectory, goals, and scale.

Contact us to learn more.