Lutterworth Ecommerce Distribution Centre:

The Solution: A Complete Warehouse Identification Package

Fortega provided an integrated identification solution covering rack locations, aisles, pedestrian routes, MHE traffic areas, external yards and structural columns.

The package combined durable printed polyester labels, large-format aisle signage, high-performance resin floor markings, thermoplastic external markings and specialist column coating.

71,000 VNA Rack Labels

Fortega manufactured 71,000 VNA rack labels, each measuring 190mm x 50mm.

Produced from durable polyester with permanent adhesive backing, the labels featured full-colour printing with colour coding by rack level.

The labels were designed specifically to allow operators working on man-up forklift trucks to identify and scan locations while working high in the rack face.

This provides clear location identification at the point of operation, supporting accurate warehouse processes in a VNA environment.

4,528 Multi-Level Rack Labels

A further 4,528 multi-level rack labels were produced at 800mm x 70mm, with five rack levels incorporated into each label and placed on the lower beams.

The labels used full-colour printing and level colour coding to provide clear identification across multiple storage positions.

Their large format was designed to allow MHE operators to identify and scan locations from ground level.

26,000 Wide Aisle Rack Labels

Fortega also supplied 26,000 wide aisle rack labels, measuring 220mm x 70mm.

Again manufactured from polyester with permanent adhesive backing, these labels featured full-colour printing and level colour coding. They were used for condensed storage and pick-face identification, creating a consistent location identification system across the facility.

Aisle Signage and Traffic Management

To support navigation and traffic management, Fortega supplied 196 two-faced aisle marker signs.

Each sign featured two 600mm x 600mm faces, manufactured from plastic and printed in full colour.

The signs incorporated:

• Aisle and bay numbers
• One-way route instructions
  • No-entry and directional information

The signage helped provide clear visual guidance throughout the facility and supported the site’s internal one-way traffic system.

Floor Marking Built for a Demanding Environment

Warehouse floor markings have to do more than look clear on day one. In a busy distribution centre, they need to withstand continuous pedestrian and MHE traffic.

Fortega therefore used high-performance epoxy resin floor marking, applied to shot-blasted concrete to maximise adhesion and durability.

The internal marking package included:

Pedestrian Walkways

Yellow 100mm wide line tramlines were used to clearly define pedestrian routes throughout the facility.

Pedestrian walking symbols were also installed to reinforce designated walking areas and communicate the intended use of specific passageways.

Pedestrian and MHE Crossings

Black-and-white zebra crossings were installed at pedestrian and MHE intersections, providing highly visible crossing points where different traffic movements meet.

MHE Traffic Routes

Outer MHE traffic lines were installed to define the extent of vehicle routes, with dashed dividing lines used to separate traffic areas.

Together, these markings provide a clear visual framework for the movement of people and MHE throughout the warehouse.

External Yard Marking

Fortega’s scope also extended outside the building.

External thermoplastic markings were installed across yard areas to identify:

• Trailer storage areas
• Bay parking
• Pedestrian walkways
• Walking routes and symbols

Thermoplastic materials provided a durable solution for the external environment and the demands of regular yard traffic.

Installation: Working Around a Live Construction Programme

One of the most important aspects of the project was the installation strategy.

Fortega used a multi-phase installation programme for the rack labels and signage, aligning its activities with rack construction and data validation schedules.

Rather than requiring the entire facility to be available simultaneously, installation could progress in controlled stages.

This was particularly valuable on a project where multiple specialist teams were working at the same time.

Fortega’s installation teams worked alongside other suppliers to coordinate activities and help maintain the wider project programme.

The phased approach provided other contractors with the time required to complete critical stages, including:

• Pallet racking
• Pick modules
• Conveyors
• RF network installation and testing
• MHE delivery
• MHE testing
• Operator training
• Data validation

This collaborative approach helped keep the various project workstreams moving towards the common goal: getting the distribution centre ready for ecommerce fulfilment operations.

Controlled Floor Marking Installation

The floor marking programme was completed as a single-phase installation but divided into carefully managed zones.

This allowed other teams to continue moving through the facility before and after individual areas were completed.

It also provided the required curing time for the floor marking materials and enabled Fortega’s teams to work safely without unnecessarily disrupting other site activities.

The Result

Fortega successfully delivered a large-scale warehouse identification and safety marking programme for one of the UK’s major new ecommerce logistics facilities.

The completed package included more than 101,000 rack labels, almost 200 aisle marker signs, extensive internal and external floor marking and specialist structural column painting.

Most importantly, the installation programme was coordinated around the wider construction and commissioning schedule, allowing multiple suppliers and trades to work together towards the facility’s operational launch.

Delivered by Fortega

101,528 rack labels – VNA, multi-level and wide aisle identification

196 aisle marker signs – Large-format, double-faced directional signage

High-performance internal floor marking – Epoxy resin applied to prepared concrete

External yard marking – Durable thermoplastic pedestrian and traffic markings

Structural column coating – Specialist coating to 5 metres high

Full installation service – Phased delivery coordinated with multiple contractors

A Project Fortega Was Proud to Deliver

Gareth Fairhurst of Fortega was proud to be involved in such a high-profile project and to work alongside the numerous suppliers and trades responsible for bringing the facility to life.

“Our teams faced and took on the challenge as they have for many years. The massive projects are less common than others, but we thrive on the challenge and satisfaction of completing such impressive projects.”

For Fortega, the project demonstrated the importance of more than simply supplying high-quality warehouse identification products.

It showed how planning, manufacturing, installation expertise and collaboration can come together to deliver complex projects against demanding deadlines.

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