Client Challenge: Limited Storage Capacity for Aircraft Fleet
A long-standing client in the aviation sector approached Crating Solutions UK Ltd with a significant storage challenge. The client owned a fleet of 32 aircraft and helicopters but only had the available space to store eight at any one time. The root of the problem? The sheer size of the aircraft rotor blades — some extending up to 8 meters in length — which made the aircrafts too wide and impractical to store efficiently in the available space.
Our Approach: Reducing Space by Rethinking Storage
After assessing the site and the client’s requirements, the Crating Solutions team proposed a practical and innovative approach: rather than storing the aircrafts as a whole, we asked the client to remove each rotor blade to enable us to securely pack each rotor blade into custom-built timber crates. This strategy would dramatically reduce the overall space each aircraft required, without compromising the integrity or safety of the components.
Bespoke Crating: Designed for Protection and Practicality
Our team designed and built a series of robust, ISPM 15-compliant timber crates specifically for the rotor blades. Each crate was constructed with careful consideration of the blade length, weight, and fragility, ensuring secure containment for both short and long-term storage. All crates were built to British Standard BS 1133, ensuring maximum protection from environmental factors and mechanical damage.
With precision packing methods and high-quality materials, our expert team successfully packed the rotor blades of all 32 aircrafts, organising and labelling each crate for easy identification and access.
On-Site Packing and Client Collaboration
The rotor blade removal was arranged by the client, and Crating Solutions worked closely with their team on-site to ensure a smooth and coordinated process. Once the rotor blades were detached, our mobile packing unit stepped in to handle the packaging and secure placement of each rotor blade into its designated crate — all on the client’s premises. This eliminated the need for transporting oversized components off-site, saving time and reducing risk.
The Outcome: 32 Aircraft, One Smart Storage Solution
By removing and securely storing the rotor blades into custom built crates, Crating Solutions successfully freed up enough space for all 32 aircrafts to be stored on the client's land — a fourfold improvement from the original capacity.
This project demonstrated our ability to deliver creative, space-saving solutions under pressure. It also highlighted the value of bespoke timber packing in scenarios where traditional storage simply isn't practical.
Need Help with a Complex Storage or Packing Problem?
Whether you're dealing with limited space, oversized equipment, or sensitive components that require specialist handling, Crating Solutions can help. Get in touch with our team today to discuss how we can design a tailored solution that meets your needs and exceeds your expectations.
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