What’s really in that stack? (And why it’s costing you more than you think)
June 19, 2025
Block-stacked, or bulk storage, inventory might be the unsung hero of space-saving in your warehouse. But it could also be the silent saboteur of your operations.
You know what’s supposed to be in each stack. But what’s actually there? That’s where things get fuzzy.
In high-density storage zones, where pallets are stacked two, three, even five deep, visibility is often more guesswork than fact. And that lack of visibility comes at a cost: manual checks, missing stock, last-minute errors, and serious delays. Yet for years, most warehouses have simply accepted this trade-off.
The invisible zone in modern warehousing
Block-stacking isn’t new. It’s a proven way to maximise space, especially when racking systems aren’t feasible or when goods are too bulky or bundled to be shelved. It’s widely used in industries like FMCG, 3PL, and retail, where floor space is a premium. But despite its ubiquity, block-stacked inventory remains one of the hardest areas to monitor accurately.
Why?
Because once the first row of pallets goes down, the rest disappear behind it. No barcode in sight. No line of sight. And no way to confirm contents without disrupting the stack or climbing in manually.
That creates a black hole in your warehouse data.
The cost of not knowing
Here’s what typically happens:
- Mismatches with the WMS are only discovered after something goes wrong.
- Manual checks are required, pulling workers away from higher-value tasks.
- Replenishment planning is based on assumptions rather than facts.
- Labour costs climb because someone has to count what automation can’t see.
All of this adds up to inefficiency, lost time, and lower stock accuracy. And the longer it takes to spot a discrepancy, the more disruptive (and expensive) it becomes.
A new lens on block-stacked goods
That’s why we developed Dexory’s Block Stack feature, to automate what was previously invisible.
Using advanced LiDAR, 3D spatial mapping, and machine learning, our robots can:
- Accurately detect and count goods in block-stacked bays
- Identify bundled or palletised stock even when barcodes aren’t visible
- Provide photo documentation for remote verification
- Flag discrepancies in real-time for fast investigation
More than visibility, it’s actionable intelligence, delivered daily, without disrupting operations.
Built for the real world
Warehouses are messy. Pallets aren’t always aligned. Labels fade. That’s the reality. And it’s why most automation tools fail in block-stacked zones. They depend on clear labels, clean angles, or predefined layouts. But Dexory’s Block Stack feature thrives in that complexity.
In testing, we’ve achieved:
- ≥95% accuracy on bundle counts in hygienic block-stacked bays
- Real-time exception detection when WMS and scan data don’t match
- Zero disruption to site operations
The robot simply does its job, weaving through aisles and capturing the truth, every time.
What happens when you know what’s there
The impact of block stack visibility isn’t subtle. Once you eliminate the guesswork:
- Stock accuracy improves dramatically
- Replenishment cycles tighten, driven by real need
- Labour is freed up, with fewer manual investigations
- Customer service improves, thanks to fewer fulfilment delays
- Space can be optimised, using real data on stack height, density, and bundle types
In other words: better control, lower costs, and smoother operations.
How one operator cut counting time by 70%
At one Dexory client site using block stacking for fast-moving bundled goods, manual counting used to take an entire shift. With DexoryView and the Block Stack feature:
- Daily scans replaced weekly spot checks
- Count accuracy jumped to 96%+
- Time spent on stock validation dropped by over 70%
The result? Faster decisions. Less firefighting. More confidence in the numbers.
Is it time to see what you’re missing?
You don’t need to rip up your storage strategy to gain control. You just need to make the invisible visible.
Our Block Stack feature gives you eyes where you had none, turning the most overlooked part of your warehouse into a source of clarity and control.
So the next time someone asks, “What’s in that stack?”, you’ll know.
Want to see how it works in your environment? Book a personalised demo