How much can a distribution centre save with PVC strip curtains?

The Birmingham distribution centre case achieved 18% reduction in gas consumption, saving an estimated £52,000–£61,000 per year across 12 bays. Payback was 2.2 months on a total project cost of £11,000.

Do heavy-duty strip curtains slow down forklift operations?

No. Properly specified swivel hinge rail strip curtains allow continuous forklift access without stopping. The transit time through a strip curtain is negligible.

Can PVC strip curtains prevent birds entering a warehouse?

Yes, significantly. The Midland Express case reduced bird sightings from 15–25 per week to 0–2 per week after installation.

How often do forklift strip curtains need replacing in a busy DC?

In very high traffic bays (200+ transits daily), expect to replace 15–25% of strips per bay every 6 months — approximately £100–£200 per bay per year in replacements.

How to phase strip curtain installation at a large facility without disruption?

Install bay by bay over consecutive weekends. Brief staff before each phase. Prioritise highest-traffic and most exposed bays first. A two-person team can typically complete 3–4 standard bays per day.

Case Study: Forklift-Grade Strip Curtains for Distribution Centre

Last updated: April 2026

Client Background

Midland Express Logistics Ltd operates a 120,000 sq ft ambient distribution centre on the outskirts of Birmingham, serving retail clients across the Midlands and North West. The facility runs three shifts, 5.5 days per week, with a fleet of 18 counterbalanced forklifts and 12 electric pallet trucks. Eight of the 16 loading bay doors had no barrier other than the roller shutter, which was opened at the start of each shift and closed at the end — leaving bays completely open to the external environment for 14–18 hours per day.

The Challenge

Energy cost: Gas heating bills had risen to £340,000/year. Analysis estimated 20–25% attributable to heat loss through open bay doors.
Pest pressure: Birds had become a persistent problem, entering through open bay doors. Pest control costs exceeded £8,000/year. Bird fouling on pallets had resulted in two customer complaints and one product rejection.
Temperature compliance: Confectionery and fresh produce clients required temperature documentation. Monitoring showed bay-adjacent storage areas frequently exceeding 18°C maximum during summer.
Staff comfort: Cold draught complaints from warehouse staff, particularly in north-elevation bays exposed to prevailing winter winds.

Solution Selected

Bays 1–8 (High-Traffic North Elevation)

Eight bays, 4.0m wide × 4.2m high, 120–240 daily forklift transits:

Strips: 300mm × 4mm standard clear PVC, made-to-measure at 4,170mm
Rail: Heavy-duty swivel hinge rail, 4.0m per bay
Overlap: 50%; 26 strips per bay at 150mm pitch
Yellow safety strips at top 500mm of each curtain (raised fork warning zone)

Bays 9–12 (Medium-Traffic West Elevation)

Four bays, 3.5m wide × 3.5m high, 20–40 daily transits:

Strips: 300mm × 3mm clear PVC, made-to-measure
Rail: Standard swivel hinge rail

All 12 bays fitted with "LOWER FORKS BEFORE ENTERING" signage and floor chevrons. Total project cost: £11,000 + VAT (materials + contractor installation).

Results Achieved (6-Month Review)

Gas consumption reduction: 18% year-on-year
Estimated annual saving: £52,000–£61,000
Projected payback: 2.2 months
Bird sightings inside facility: reduced from 15–25 per week to 0–2 per week
Pest control contract cost: reduced by £4,200/year
Zero product rejections due to contamination since installation
Summer ambient temperature in bay-adjacent storage: maximum 17.8°C (within 18°C compliance requirement)

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Case Study: Forklift-Grade Strip Curtains for Distribution Centre — Birmingham