Plan Your Warehouse Expansion with a Digital Twin – Before You Build

August 18, 2025

A “digital twin” lets you simulate your warehouse expansion before investing in construction or automation.

MHS Lift uses layout modeling and 3D tools to help you visualize flow, test scenarios and avoid costly mistakes.

Why is planning critical before expanding a warehouse?

Warehouse expansion is a major capital investment. Yet many companies rush into construction or equipment purchases without fully modeling their future layout or flow. The result? Workflow bottlenecks, costly retrofits and poor ROI.

Smart operators want to:

  • Simulate different layout options
  • Visualize throughput under peak load
  • Test equipment fit and racking heights

What is a digital twin in warehouse design?

A digital twin is a virtual model of your facility. It mirrors real-world dimensions and operations. MHS Lift uses these tools to:

  • Model your layout in 3D
  • Test travel paths and automation scenarios
  • Simulate pick rates and product flow
  • Forecast capacity before committing to build

What design elements can we simulate?

Digital twins can test:

  • Aisle widths and racking placement
  • Lift equipment turn radius and clearances
  • Conveyor system paths
  • Loading dock usage under peak conditions
  • Picking strategies and operator travel time

This helps avoid guesswork and builds smarter from day one.

Who benefits from warehouse simulation?

Warehouse simulation is ideal for:

  • Companies planning facility expansions or new builds
  • 3PLs evaluating new client requirements
  • Operations adding automation or new product lines
  • CFOs seeking more accurate ROI forecasts

FAQ

Q1: What software do you use for warehouse simulation?
A1: MHS Lift uses leading 3D modeling and digital twin platforms tailored for logistics and warehouse design.

Q2: Do I need CAD files of my current facility?
A2: CAD files help, but we can also work from facility measurements or blueprints.

Q3: Can we simulate throughput before choosing automation?
A3: Yes. Simulation lets you compare automated vs manual flow before investing.

Q4: What’s the ROI of simulation planning?
A4: Preventing even one layout error or equipment mismatch can save tens of thousands in rework and delays.

Design smarter, not harder.

Talk to MHS Lift about digital twin modeling and warehouse simulation services before you build or automate. Give us a call today!