22,000 parts always at hand: AR Racking and Begra streamline BYD Europe’s logistics

• 14,000 m² of scalable capacity for immediate after-sales service
• Installation completed in ten days with high-bay racking and maximum flexibility

AR Racking, in collaboration with its official distributor in the Netherlands, Begra, has completed the full transformation of BYD Europe’s logistics centre in Zevenbergen. The project replaces a 3,000 m² facility with a 14,000 m² platform capable of housing 22,000 perfectly organised spare parts, reinforcing the operational continuity of the company’s electric bus fleet across the continent.

The intervention began with a clear diagnosis of the initial situation. “When I arrived on my first day of work,” recalls Ron Heijnen, warehouse manager at BYD Europe, “I walked into a cluttered storage space that looked more like a garage than a professional warehouse; pallets were everywhere and nothing made sense, so I wondered what this was going to become.” Rapid growth in Europe had amplified the logistical pressure: “BYD grew rapidly in Europe, and that’s great because we really want to contribute to a greener world, but that growth also brought quite a few challenges, especially in logistics,” he explains.

Three requirements were therefore set: room for 22,000 components, a scalable system, and optimum use of the building’s height. “In logistics you pay per square metre, not per cubic metre, so we had to build upwards—vertical storage was essential,” notes Heijnen. AR Racking’s design maximises usable volume with high-bay racking, incorporates adjustable picking levels that can be re-configured within minutes, and includes cantilever lines for the longest components. Installation was completed in just ten days, half the original schedule, without disrupting daily dispatches thanks to coordinated work between AR Racking’s and Begra’s technical teams.

Execution speed proved decisive. “The installation was supposed to take two weeks but was finished in one week and two days,” says Robert Poh, team leader at the warehouse, who also values the system’s adaptability: “What I like about the racks is that you can easily adjust them; they respond quickly to customer requests and deliver what is needed without delay.” With the new platform, part location is instantaneous and internal travel distances have been significantly reduced, minimising vehicle downtime and the associated costs. “The difference with the old warehouse is night and day; now each part is where it should be and leaves on time, so we can really look ahead,” concludes Heijnen.

The solution allows future expansion without structural changes and all components comply with European safety and traceability standards, aligning with BYD Europe’s commitment to zero-emission transport. The project underscores AR Racking’s ability to deliver tailor-made solutions that combine innovation, quality and rapid execution, supported by the operational proximity of its distributor network.