How a 60,000 sq ft warehouse got WiFi that actually works.
UK third-party logistics operation, WMS handhelds dropping connection mid-pick, voice-pick headsets unusable in three of six aisles, scanner reboots every shift. Here's how we redesigned the network so it just works.
What we hear every week.
The frustrations behind why businesses search for warehouse wifi upgrade case study in the first place. If any of these feel familiar, the fix is straightforward.
Handheld scanners losing connection
WMS handhelds dropping connection mid-pick. Operators having to re-scan, re-confirm, sometimes restart the device. Pick rate halved in problem zones.
Voice-pick headsets unusable in aisles
Three of six aisles had no usable WiFi for voice-pick. Operators in those aisles working off paper picks — slower and error-prone.
Daily reboot culture
Shift supervisor power-cycling access points every morning. WiFi 'mostly working' but never reliably. Symptom of overloaded consumer-grade kit doing a job it was never designed for.
IoT sensors failing in extremes
Cold storage IoT sensors disconnecting in winter; rooftop solar inverters dropping in summer heat. Consumer kit not rated for the environments.
What we recommended and installed
Full site survey came first — two-day walkthrough with signal-measurement kit identifying interference sources (metal racking, refrigeration units, neighbouring industrial WiFi). Design specified 18 industrial-grade access points (Ubiquiti UniFi U6-Enterprise) across the warehouse, three more for the office mezzanine, plus a separate VLAN for IoT sensors and a guest network for visiting drivers. Central controller with proactive monitoring. Cable runs done over three weekends to avoid disrupting operations. Cutover scheduled for a Saturday with parallel-running of the old kit for 48 hours.
The Telexico approach to warehouse wifi upgrade case study.
Six things our customers consistently tell us matter.
Site survey-driven design
Access point count and placement designed around actual signal measurement, not guesswork.
Industrial-grade access points
Ubiquiti UniFi U6-Enterprise — designed for high-density industrial environments, dust and temperature tolerant.
Voice-pick coverage everywhere
Every aisle now has reliable WiFi for voice-pick and WMS handhelds — pick rate restored across the whole floor.
Segmented VLANs
Operations on one VLAN, IoT sensors on another, guest drivers on a third — properly isolated and prioritised.
Central management dashboard
Operations team sees every connected device, every access point, every issue — proactively, not reactively.
Proactive monitoring
Telexico monitors the network 24/7 — issues identified and addressed before they cause operational disruption.
Why this setup fits UK logistics
Warehouse WiFi is not office WiFi. The challenges are completely different: massive open space, metal racking creating RF shadows, voice-pick and WMS demanding low latency, IoT sensors in environmental extremes, hundreds of devices connecting simultaneously. Generic 'enterprise WiFi' approaches usually fail in warehouses because they're designed for offices. Industrial-grade kit and site-survey-driven design are the only reliable way.
How it works for businesses like yours.
Three real-world setups we deliver across the UK.
UK 3PLs and contract logistics
Multi-shift warehouses running WMS, voice-pick, mobile scanners — exactly the workload that breaks consumer WiFi.
Manufacturing facilities
Production floor scanners, MES integration, IoT sensors on production lines — same connectivity demands, same need for industrial-grade design.
Cold storage and food production
Environmental extremes (refrigeration, washdown areas, humidity) — access points rated for the environment plus dedicated IoT VLAN for monitoring sensors.
The ongoing support relationship
Beyond the install: 24/7 proactive monitoring, quarterly review of network performance, named Wolverhampton-based account manager, and on-site engineering response when something needs hands-on attention. Network changes (adding access points for new mezzanines, reconfiguring VLANs for new equipment) handled as part of the managed service rather than each as a separate quote.
What you actually get from Telexico.
Honest about scope. No aggressive sales tactics, no surprise renewal jumps, no tier-1 call-centre triage. Real UK engineers, transparent pricing, one provider relationship across the stack.
UK-based provider
Wolverhampton-headquartered. Engineers cover the West Midlands daily; UK-wide install via our partner network. Real UK engineer support, UK data residency, UK contractual relationship — not US-routed SaaS.
Real engineer support
When you call Telexico, you reach someone who can actually fix things. Response SLA backed by real engineering capacity rather than call-centre headcount. Named account manager for ongoing customers.
Free infrastructure review
Every engagement starts with a no-obligation audit of your current setup. Honest recommendation — sometimes that's "stay with your current provider after negotiation." We'd rather be honest than oversell.
Transparent pricing
What you sign for is what you pay — including renewal. No teaser pricing that jumps 30-100% at year two. No mid-contract CPI shock. Predictable multi-year cost from day one.
One provider, one platform
Broadband, hosted VoIP, business WiFi, AI Receptionist, 4G/5G failover, CCTV consolidated onto one Telexico relationship. Single bill, single support number, single engineer when something needs attention.
Migration project-managed
Switching to Telexico isn't DIY. We handle contract audit, notice timing, ordering, parallel running, cutover, old-provider close-out. Customer-visible disruption typically measured in minutes.
Tailored around your business.
Tell us what you have now and what's frustrating you. We'll come back with a tailored review of where we can simplify, consolidate or improve it — no fixed-package pressure, no hard sell.
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Free infrastructure review
Send us your current setup. We'll review what you have, what you pay, and where we can simplify.
Frequently asked questions
How long did the warehouse upgrade take?
Six weeks from survey to cutover. Two days for the site survey, two weeks for kit ordering and configuration, three weekends of cabling work, one weekend cutover with parallel-running. Operations carried on uninterrupted throughout.
How many access points does a warehouse like this actually need?
Depends entirely on the building. This 60,000 sq ft site needed 18 access points in the warehouse plus 3 in office mezzanines — densities driven by the site survey, the device count, and the workload mix. Generic 'one per 2,000 sq ft' rules-of-thumb usually under-spec for high-density industrial use.
What was different about the new access points vs the old ones?
Industrial-grade rather than consumer. Higher capacity, better roaming, proper VLAN segregation, central management, environmental tolerance, longer support lifecycles. Same idea as the difference between a workshop tool and a DIY one.
Did operations have to stop during install?
No — cabling work was scheduled around shifts (mostly weekend nights), kit installation was non-disruptive, cutover happened on a Saturday with parallel-running so any issue could be rolled back instantly. Zero operational downtime.
What about the voice-pick system specifically?
Voice-pick is genuinely demanding — low-latency, always-on, headsets roaming between access points constantly. Industrial-grade access points with proper roaming configuration solved it cleanly. The operator experience went from 'unusable in three aisles' to 'works everywhere'.
How is the network managed ongoing?
Central controller monitored by Telexico 24/7. Performance dashboards visible to the operations team. Quarterly reviews of capacity, utilisation and any drift in coverage. Changes (adding APs, reconfiguring VLANs) handled as part of the managed service.
Does this scale to bigger warehouses?
Yes — the same approach scales to multi-hundred-thousand-sq-ft sites with proportionally more access points and (for very large sites) multiple controllers. Site survey is the foundation; everything else scales from it.
Apply this to your business?
Reading the guide is one thing; applying it to your specific operation is another. Send us your current setup — we'll review what you have, what fits, and where to start. No hard sell, no fixed-package pressure.