Project Background
With the rapid rise of e-commerce and quick-commerce fulfillment in the Middle East, Falcon Express Logistics (fictional but styled to match regional enterprises) needed to build a compact, high-density automated warehouse in downtown Dubai to support its 2-hour urban delivery service.
Due to strict space constraints and extremely high land costs in central Dubai, the customer required a solution that offered:
- A minimal footprint
- Height limitation below 5 meters
- High-density storage capability
- Automated operations
- High stability with low maintenance needs
After evaluating multiple suppliers, Falcon Express selected Dongjian’s Box-Type Bull-Leg Automated Warehouse as the core technology for its “urban micro-fulfillment center” upgrade.
Project Scale
| Parameter | Data |
|---|---|
| Total Warehouse Area | 160 m² (prime city-center location) |
| Internal Clear Height | 4.5 m |
| Racking Footprint | 36 m² |
| Effective Storage Capacity | 512 box-type locations |
| Operating Mode | Automated storage + semi-automated picking |
| Go-Live Time | 28 days (installation + commissioning) |
Key Highlights
1. Ultra-High Storage Density in Limited Urban Space
Although the Dubai site has a restricted height profile, the bull-leg box-type structure maximizes every centimeter of the 4.5-meter space:
- Achieves 512 effective storage locations
- Improves storage density by 230% per square meter
- Ideal for Middle Eastern markets with high rental costs and dense urban logistics
- Enables the customer to achieve mid-size warehouse capacity within a compact footprint
2. Efficient Turnover Designed for Rapid Deliver
The system supports fast inbound and outbound operations, perfectly matching Falcon Express’s quick-commerce model:
- Storage/retrieval time per tote reduced by 43%
- Daily order processing volume increased from 1,800 to 3,200 orders
- Automated picking paths reduced walking distance by 70%
During peak seasons such as Ramadan and major shopping festivals, the warehouse maintained stable, high-throughput performance.
3. Structural Innovations — Guide Plate + H-Steel Base
Falcon Express highlighted Dongjian’s structural innovations as a key differentiator:
Guide Plate Advantages
- Improves box positioning accuracy
- Prevents tilting or slipping during movement
- Particularly suited for Dubai’s cross-border goods with light, small, and irregular packaging
H-Shaped Steel Bottom Advantages
- Enhances overall system stability
- Strengthens load-bearing capacity at the base
- Performs reliably under large temperature variations (high outdoor heat + air-conditioned warehouse)
The structural design passed local safety inspection on the first submission.
Project Results
| Indicator | Before | After |
|---|---|---|
| Effective Storage Capacity | 210 | 512 (+144%) |
| Daily Order Processing Volume | 1,800 | 3,200 (+78%) |
| Workforce Requirement | 12 staff | 6 staff (–50%) |
| In-Warehouse Damage Rate | 1.9% | 0.3% (–84%) |
| Delivery Response Time | 3.5 hours | 1.2 hours |
The project elevated Falcon Express’s micro-fulfillment operations to one of the highest performance levels in the Dubai urban logistics sector.
