Outgrowing Capacity: Hira Industries Solves Space Constraints with Vertical Warehouse Expansion, Creating One of the GCC’s Largest Facilities
Hira Industries has addressed a critical capacity challenge after outgrowing its previous warehouse infrastructure, investing in a high-density, vertically optimised facility that now ranks among the largest in the GCC.
As the company expanded its global footprint across the GCC, India, Southeast Asia and the United States, increasing demand placed sustained pressure on storage and logistics operations. Limited floor space, combined with growing inventory volumes, required a strategic shift in how capacity could be scaled without expanding the physical footprint.
To overcome this challenge, Hira implemented a vertical storage strategy, extending racking systems to heights of up to 15 metres in order to maximise available cubic space. Material handling specialist Combilift, alongside trusted local dealer Kanoo Machinery UAE, supported Hira with its warehouse transformation.
The team conducted a comprehensive site survey and in-depth operational analysis of Hira’s facility. After that, the Combilift warehouse design team developed an optimised layout tailored specifically to Hira’s operational requirements, ensuring smoother material flow, improved accessibility, and more efficient use of storage capacity. In addition, the articulated Aisle Master forklift was selected as the ideal handling solution due to its narrow-aisle manoeuvrability and high lift capabilities, enabling Hira to increase overall space utilisation while maintaining operational efficiency significantly.
“Our storage capacity has increased by almost a 40%,”
highlighted Shyju Pillai, Warehouse and Logistics Manager at Hira Industries. As a result, pallet capacity has grown from approximately 1,000 pallet positions to nearly 4,000.
Aside from the substantial increase in storage capability, this transformation has enabled Hira to operate at a scale that positions the facility among the most advanced warehouse environments in the region.
“A key challenge for us was space, particularly height,”
said Umesh Unni, Operations Director at Hira Industries. “We needed a solution that allowed us to grow within our existing footprint while maintaining efficiency and control across the operation.”
A fleet of 4 Aisle Masters was introduced to support the new high-density layout. Designed for narrow aisle operation and high-level picking, the equipment enables efficient navigation and maximises accessibility across the full height of the racking system.
“When we expanded the plant, optimising space was critical,” added Pillai. “By going vertical and implementing the right equipment, we’ve been able to significantly increase capacity while improving the overall flow of materials.”
Safety and operational efficiency were central to the upgrade. Each Aisle Master incorporates integrated camera systems, laser guidance, and height preselection functionality, reducing operator strain and improving precision when placing and retrieving loads at height.
“The ability to preset lift heights and operate with added visibility has made a real difference,” Pillai continued. “It allows our operators to work faster and more safely, particularly when handling goods at height.”
The enhanced setup also allows for continuous movement between warehouse zones, supporting the handling of both raw materials and finished goods. This ensures consistent workflow across the operation and strengthens Hira’s ability to meet production demands and customer delivery timelines.
“This investment has not only increased our storage capacity, but also improved how we manage and move materials across the facility,” Unni concluded. “It’s a key step in supporting our long-term growth.”
By rethinking warehouse design and investing in vertical capacity, Hira Industries has turned a space constraint into a scalable logistics solution, reinforcing its operational resilience and supporting continued growth across global markets.
