Ideal Electrical enhances warehouse safety with Aerofast
Ideal Electrical’s Auckland distribution centre is the backbone of the company’s nationwide logistics operation, handling thousands of SKUs stored across 700 bays. With products varying widely in size, shape, and packaging, the challenge of keeping people safe while maintaining efficient operations is ever present.
Phillip Eades, Ideal Electrical’s national health, safety and environmental manager, says a hazard review of the DC – particularly the 3PL area – highlighted a growing concern. “The type of product we store in the 3PL area is really varied. These items are often returned goods from our client’s network – sometimes not nicely packaged or stacked. If something fell from the higher bays, it could cause serious injury.”
Protecting workers from falling stock was essential, but accessibility could not be compromised. “We needed to protect people from falling stock but still allow our team to access parts easily. It could not be something that added more complexity or got in the way of productivity,” says Eades.
Options such as pallet collars, steel cages, and fixed structures were considered, but each created its own problems. Fixed cages, for example, limited flexibility.
“As soon as you start putting other structures like steel cages into the bay, you reduce your flexibility. Sometimes we need to move full pallets in and out – so you would have to remove that structure and find somewhere to store it,” he says.
Finding the right partner
Ideal Electrical turned to Aerofast, a New Zealand manufacturer already known to the company, to explore whether customised racking nets could provide a better solution.
“I had seen their products before and knew they were New Zealand made. That was important to us – not just from a sustainability point of view, but also because it meant local expertise, faster response times, and better communication,” says Eades.
Aerofast worked closely with Ideal Electrical to design a system suited to the DC’s varied needs. Initial trials in selected aisles allowed staff to test the nets without disruption. Although hesitant at first, the warehouse team quickly adapted once they saw little change to their day-to-day process.
Refinements through collaboration
The trials also created opportunities to refine the design. Ratchets replaced cam buckles to deliver more tension across larger nets, while high-visibility yellow straps were added through the centre for easier monitoring. Aerofast even suggested weaving Ideal Electrical’s company name into the nets – a value-add that improved brand presence while providing a quick visual cue for unsecured bays.
Installation was straightforward. Aerofast supplied an on-site briefing, printed instructions, and a QR code linking to a video guide. “Our DC manager had his team installing them in no time. After a short briefing, they were able to get started, and around 300 nets have been installed to date, with more to come,” Eades says.
Delivering results
The rollout of Aerofast’s racking nets has produced tangible safety and efficiency gains. Cost was a major factor.
“Other options like metal cages were extremely expensive,” says Eades. “The nets gave us the safety outcome we needed at a far more reasonable cost.”
Crucially, operations were not disrupted. The nets slide open like curtains, allowing one-handed access even at height. Staff quickly embraced the system once they saw it had minimal impact on workflow.
Other benefits included:
• Flexible redeployment, with nets that can be folded away or shifted to another bay.
• Improved safety compliance under the Health and Safety at Work Act.
• Quick installation by internal staff without specialist tools or contractors.
• Clear visual safety cues through high-vis straps, ensuring unsecured nets are easy to. spot
• Sustainable sourcing and local support from a New Zealand manufacturer.
Customer verdict
Eades says the project has delivered exactly what was needed.
“Aerofast delivered a safe, easy-to-use system made to our specs. They were responsive, knowledgeable, and brought smart, practical ideas that really improved the outcome.
“Communication and support were excellent throughout – Aerofast provides a really great service – and the product has performed exactly as promised. Being New Zealand-made was a key factor for us. We would absolutely recommend Aerofast to any warehouse operation needing a flexible, cost-effective safety solution.”
Sponsored content: For more information phone +64 03 376 4028, email tiedowns@aerofast.co.nz or visit www.aerofast.co.nz.