Industrial facilities constantly battle the same challenge: how to store more while taking up less space. When growth and production ramp up, storage solutions need to keep pace. But what happens when your ceiling is too low to accommodate traditional vertical storage?
That was the problem Hirschvogel Incorporated faced in its Columbus, Ohio facility. With limited storage capacity and expanding operations, they needed a space-saving solution that didn't require knocking down walls or raising the roof.
Their answer? Thinking outside the box — literally.
The Problem: Hirschvogel's Growing Pains
Hirschvogel, a subsidiary of the Hirschvogel Automotive Group, has been a key player in cold and warm forged parts production since 1988. Their Columbus, Ohio, facility is a high-volume manufacturing hub, producing ready-to-assemble components for the automotive industry.
By 2016, growth was straining their dye prep area. Traditional rack shelving couldn't keep up with increased inventory needs, and the company was running out of room.
Jason Cudak, a project manager at Hirschvogel, saw that other company facilities were using Vertical Carousel systems. But Columbus had a problem: its 15-foot ceilings weren't high enough to maximize the benefits of vertical storage.
"We loved the potential of the vertical carousel and were pretty much sold on its upside early on," said Cudak. "At the time, we had started to process more goods and space was becoming increasingly valuable. Despite our relatively low ceilings, we knew that to get the most bang for our buck we needed to go as high as we possibly could."
The Solution: Thinking Beyond the Ceiling
Instead of limiting their storage to the building's height, Hirschvogel and Patterson Pope's storage experts got creative. Rather than raising the roof, they extended their storage outside the facility by installing a Hänel Lean-Lift system on the building's exterior.
"In order to get a more appropriate height, we knew we'd have to install it outside the wall," Cudak explained. "We decided on the Lean-Lift from Hänel, and that's exactly what we did."
Three Lean-Lift units were installed:
- Two 35-foot-tall units
- One towering 53-foot unit
This solution allowed Hirschvogel to maximize vertical storage without modifying their existing facility footprint.
Installing a Vertical Carousel in the Dead of Winter
Innovative storage solutions often require innovative installation methods. But the biggest hurdle? Winter in Ohio.
Originally, the plan was to install the Lean-Lifts first, then build the protective structure around them. But because of their height, the team needed something to anchor the units at their apex — which meant partial construction, then installation, then final construction.
"We had to partially install the framework of the addition, then put some of the Hänel Lean-Lift units in, then complete the addition, and finally finish the product installation," explained Cudak. "There were a lot of steps involved and a lot of coordination."
Wind, sleet, and freezing temperatures added another layer of complexity. But with careful planning and collaboration between Hirschvogel and Patterson Pope, the installation was a success.
The Results: More Space, Better Efficiency
Once the Vertical Carousel units were up and running, Hirschvogel saw immediate benefits:
- More storage capacity in a smaller footprint
- Freed-up floor space, allowing for additional equipment installation (including a new furnace for part processing)
- Improved organization and faster retrieval of tooling, maintenance, and production components
"It was definitely nice to be able to work with a company that was committed to seeing the project through to the end and to have it be successful," said Cudak. "I'd definitely recommend Patterson Pope. They listen, and they're all about helping you find more than just 'a solution.' They're committed to helping you find the right solution."
Real-World Innovation in Storage
Hirschvogel's outside-the-box thinking (literally) proves that Vertical Carousels can maximize storage potential even in space-limited facilities. For manufacturers, warehouses, and industrial operations, the key takeaway is simple: Sometimes, the best solution isn't about working within your space, but expanding how you think about it.
Patterson Pope's team worked closely with Hirschvogel to design and execute a solution tailored to their exact needs — not just selling them a product, but helping them find the right answer.
Want to see how a Vertical Carousel could work for your facility? Contact a representative from Patterson Pope today to explore the details and learn how you can reclaim space, increase efficiency, and make storage work for you.
