Ethan Allen has grown into a manufacturer and retailer of furniture of international scope. It operates three saw mills, twenty manufacturing facilities, and eleven distribution centers. With storage capacity to ship its home furnishings products becoming a challenge, Ethan Allen decided to expand the capacity of its distribution facility in Kentland, Ind. By installing a mezzanine system, the company's space for case goods at this DC increased from 100,000 square feet to 315,000 square feet. The expansion had to be completed in 6 months or less. And it had to be done without disrupting normal business at the DC.

Safety also was important. Although the custom-designed mezzanine was constructed to create more space, accessibility and safety were major issues, too.

The mezzanine is well within reach of forklift trucks operating on the lower floor level. And it is sturdy enough to hold tons of furniture in cartons.

Gates open in the mezzanine railings for safety in loading or unloading of cartons at the mezzanine level.

"We considered two mezzanine suppliers, both proposed by our general contractor," recalls Jack Moll, vice president of distribution for Ethan Allen. The selected supplier was chosen for several reasons.

"It was closer to the site, thus saving on transportation expenses. It was willing to work with us to make sure the project went well. And it offered the best price," Moll says. "We saw a couple of its projects and we were impressed with the work," he adds.

Normal operations weren't disrupted during construction, explains Mike Robinson, distribution manager in Kentland. With the mezzanine system, Ethan Allen is now "able to process more products, in the most efficient manner, to our customers. This mezzanine supplier, adds Moll, "is in our portfolio as a vendor of choice, and will be considered for further expansions."

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