Modular Warehouse Solutions That Adapt to Change

In this episode of The New Warehouse Podcast, Kevin chats with Ben Hull, Director of Sales at Item America, about how modular warehouse solutions are reshaping operations. Item America, a German-based company with a growing U.S. presence, specializes in aluminum extrusion systems that allow teams to design and build custom solutions on the shop floor. 

From ergonomic workstations to AMR-compatible carts, the conversation explores how flexibility, customization, and continuous improvement are driving smarter warehouse design. Hull shares how modular thinking helps operations reduce waste, adapt faster, and create solutions that truly fit their needs.

From Industrial Legos to Custom Modular Warehouse Solutions

At its core, Item’s approach is simple but powerful. As Hull explains, “you know, a rector set, or we like to call it industrial Legos.” That comparison captures the essence of modular warehouse solutions—standardized components that unlock endless customization. Instead of relying on fixed equipment, operations can design around their exact needs.

Hull emphasizes that every solution begins with an idea. “Really, it starts with an idea. It starts with a thought. And then we just allow somebody to have the different products available to then create that idea into reality.” This mindset shifts how teams think about equipment. 

Rather than adapting processes to fit tools, they build tools to fit processes. Over time, this approach supports continuous improvement by eliminating unnecessary steps and simplifying assembly, replacing traditional welding and fabrication with faster, more flexible builds.

item Building Kit System – THE profile technology for modular, industrial applications

Why Flexibility Matters on the Floor

Warehouse environments are constantly evolving. Labor challenges, product variability, and operational shifts demand adaptable solutions. Hull points out that traditional setups often create inefficiencies. “Everything will find its way onto that cart.” That clutter leads to wasted motion and disorganization.

Modular warehouse solutions address this by creating purpose-built designs. “Everything has its place. It keeps for a very clean, lean environment.” Instead of generic carts or workstations, teams can design around specific workflows, improving efficiency and reducing waste. 

Just as important, these systems evolve with the operation. When needs change, teams can adjust rather than replace entire setups. That ability to modify rather than scrap equipment supports long-term cost savings and operational agility, especially in fast-changing environments like e-commerce and manufacturing.

How Modular Warehouse Solutions Support Automation and Ergonomics

As automation grows, modular design plays an even bigger role. AMRs require customized top modules to handle different product sizes and weights. Hull highlights the advantage of lightweight aluminum structures. “You’ve aided the ability to then put more weight on that structure, so you can move more product that way.” This directly improves throughput and efficiency.

There’s also a hidden benefit tied to energy usage. “Your runtime and your battery length extend on those AMRs.” Lighter structures reduce strain on robots, increasing uptime. Beyond automation, modular systems improve ergonomics. Adjustable workstations and tools positioned within a “golden reach” zone reduce strain and repetitive motion. These small design improvements add up, boosting productivity while supporting employee safety and comfort across shifts.

One standout example comes from Area Two Farms, where a full-scale indoor growing structure, roughly 20 feet in each direction, was built entirely using the system, showing just how far modular design can go.

Key Takeaways

• Modular systems allow warehouses to build solutions around processes, not the other way around
• Custom carts and workstations reduce clutter and improve operational efficiency
• Lightweight aluminum structures increase AMR payload capacity and runtime
• Modular designs eliminate welding and reduce the time required for assembly and changes
• Ergonomic improvements, like adjustable stations and reach optimization, reduce worker strain
• Operations can modify existing setups instead of replacing them, lowering long-term costs
• Growing adoption in the U.S. reflects a shift toward flexible, right-fit solutions over off-the-shelf equipment

Listen to the episode below and leave your thoughts in the comments.

Guest Information

For more information on Item America, click here.

To connect with Ben Hull on LinkedIn, click here.

For more information about modular warehouse solutions, check out the podcasts below. 

Warehouse Digital Transformation: Bridging ERP and the Warehouse Floor

Warehouse Trends October 2025: Data Integration, AI Voice, and Brownfield Breakthroughs

635: Integrating Fragmented Warehouse Systems with EPG’s Unified Approach