Wooster Brush Company Expands Warehouse Capacity With Selective & Push-Back Pallet Racking

Location: Wooster, Ohio
Industry: Manufacturing, Warehousing & Distribution

Partners
– Material Handling Provider: Handling Concepts
– Selective Pallet Rack Manufacturer: Bulldog Rack
– Wire Decking Manufacturer: Nashville Wire Products
– Push-Back Rack Manufacturer: 3-D Storage Systems
– Installation Contractor: Erie Industrial

Overview

The Wooster Brush Company, one of Ohio’s most respected and long-established manufacturers, recently completed a major expansion at its new Wooster North facility in Wooster, Ohio. As part of this large-scale growth initiative, the company partnered with Handling Concepts to design and implement a high-capacity pallet racking system that would support modern warehousing, manufacturing, and distribution operations.
The solution combined Bulldog Rack selective pallet racking, Nashville Wire Products wire decking, and 3-D Storage Systems push-back rack, providing both accessibility and high-density storage within the new facility. Installation was completed by Erie Industrial, ensuring a professional, safe, and efficient execution.

Client Overview: The Wooster Brush Company

Founded in 1851 and headquartered in Wooster, Ohio, The Wooster Brush Company is a leading manufacturer of paint applicators, tools, and related products serving professional and consumer markets across North America.

As demand grew and the company reached capacity at its downtown Wooster location, leadership approved the construction of a new 600,000+ square-foot manufacturing, warehousing, and distribution facility within Innovation Park. This expansion allows Wooster Brush to support continued growth while modernizing its internal logistics and material flow.

The Challenge: Designing a High-Capacity, Flexible Warehouse Racking System

With the construction of the new Wooster North facility, Wooster Brush faced several material-handling challenges:

• Designing a racking system that could support high pallet volumes
• Balancing selective access with high-density storage
• Integrating storage layout early in the building’s life cycle
• Supporting both manufacturing staging and distribution efficiency
• Ensuring long-term flexibility for growth and SKU changes

The company needed a trusted material handling partner that could collaborate directly with internal engineering and facilities leadership to develop a future-ready solution.

Collaborative Design & Engineering Approach

Handling Concepts worked closely with Tim Swift, Purchasing Manager of Capital Projects and Administration, and Joe Elwood, Industrial and Facilities Engineer at Wooster Brush.

Joe Elwood played a key role in the layout and design of the racking system, ensuring aisle spacing, rack heights, and pallet flow aligned with the building footprint, equipment, and operational goals. Handling Concepts translated those requirements into a practical, scalable racking solution using proven manufacturers and experienced installers.

This collaborative approach ensured the system was optimized before pallets ever entered the building.

The Solution: Hybrid Selective & Push-Back Pallet Racking SystemI

Handling Concepts designed and supplied a hybrid pallet storage system that included:

Selective Pallet Racking by Bulldog Rack

Selective pallet rack was installed throughout key warehouse areas to provide:

• 100% access to every pallet
• Flexibility for changing SKUs
• Easy integration with standard lift trucks
• Reliable, heavy-duty construction

Bulldog Rack was selected for its durability, domestic manufacturing, and ability to support high-capacity industrial applications.

Wire Decking Supplied by Nashville Wire Products

To complete the selective pallet racking system, Nashville Wire Products supplied heavy-duty wire decking designed to enhance both safety and performance within the new Wooster North facility.

The wire decking provides a stable, uniform surface for pallet storage while allowing light, water, and fire-suppression systems to function effectively—an important consideration in a high-volume manufacturing and distribution environment.

Benefits of the wire decking solution included:

• Improved load support across rack beams
• Enhanced fire safety and sprinkler system effectiveness
• Increased visibility and airflow throughout the rack system
• Reduced risk of pallet damage or product fall-through
• Compatibility with standard and non-standard pallet sizes

By incorporating wire decking from Nashville Wire Products, Handling Concepts delivered a complete, code-compliant racking solution that improves safety for personnel while supporting efficient warehouse operations.

Push-Back Racking by 3-D Storage Systems

To maximize storage density while maintaining efficient pallet retrieval, Handling Concepts incorporated push-back racking from 3-D Storage Systems.

Benefits of the push-back system included:

• Increased pallet positions per aisle
• Reduced aisle count
• LIFO (Last-In, First-Out) efficiency
• Smooth, gravity-fed pallet movement
• Ideal staging for high-throughput product

This combination allowed Wooster Brush to significantly increase storage capacity without sacrificing operational efficiency.

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Installation & Execution

All racking systems were professionally installed by Erie Industrial, a trusted installation partner with extensive experience in large-scale warehouse projects throughout Northeast Ohio.

The installation was completed safely, efficiently, and in alignment with the overall facility construction schedule—allowing Wooster Brush to move quickly toward full operational use of the new building.

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Results: Increased Capacity, Efficiency & Long-Term Flexibility

The completed racking system delivered immediate and long-term benefits

• ✔Maximized Storage Capacity : The push-back rack system dramatically increased pallet density while selective rack ensured flexibility where needed.
• ✔Efficient Warehouse Flow: Clear aisle layouts and proper rack configuration support smooth forklift traffic and staging operations.
• ✔Future-Proof Design: The system allows for expansion, reconfiguration, and SKU changes as production and distribution needs evolve.
• ✔Strong Cross-Team Collaboration: Early coordination between Wooster Brush engineering, Handling Concepts, and installation partners resulted in a seamless project.

Why Northeast Ohio Manufacturers Choose Handling Concepts

Manufacturers across Wooster, Cleveland, Akron, and Northeast Ohio rely on Handling Concepts for:

• Pallet racking systems (selective, push-back, drive-in)
• Warehouse layout and space optimization
• Material handling system design
• Project coordination and installation management
• Long-term service and support

Handling Concepts brings together engineering insight, trusted manufacturers, and experienced installers to deliver results-driven solutions.

Conclusion

The Wooster Brush Company’s new Wooster North facility represents a major investment in the future of American manufacturing. By partnering with Handling Concepts, the company implemented a pallet racking system that supports efficiency, safety, and growth from day one.

Through close collaboration with internal engineering leadership and the use of proven racking technologies, Handling Concepts helped ensure that Wooster Brush’s new facility is built to perform—now and for decades to come.

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