Case Study: How a 150,000 Sq Ft Distribution Center Cut Cleaning Costs by 55%

The Customer

A third-party logistics (3PL) provider operating a 150,000 sq ft distribution center in the Midwest United States. The facility handles consumer goods for e-commerce fulfillment, operating two shifts with 80+ forklifts in constant motion. Floors are sealed concrete with high traffic in shipping/receiving zones.

The Problem

The facility was paying an external cleaning company $72,000/year for nightly floor cleaning. Despite the cost, results were inconsistent — contractors changed frequently, equipment was poorly maintained, and the facility manager received complaints about tire marks and dust accumulation in pick zones. With the contract up for renewal with a 15% increase proposed, they explored bringing cleaning in-house.

The Solution

We recommended a fleet of two ride-on scrubbers — one 34-inch for main aisles and shipping docks, and one 28-inch for tighter pick zones and pack stations. Both machines equipped with lithium batteries for opportunity charging between shifts. Total investment: $18,000 factory-direct (equivalent dealer quote: $32,000).

The Results

After 6 months of in-house cleaning with factory-direct equipment, the facility reported:

• Annual cleaning cost: $24,000 (one part-time operator × 20 hrs/week + parts) — down from $72,000
• Annual savings: $48,000 — 67% reduction
• ROI: Equipment paid for itself in 4.5 months
• Floor cleanliness: Audit scores improved from 78% to 96%
• Operator feedback: 'The machine is so simple, our warehouse associate learned it in 30 minutes. We clean every night now — not just when the contractor showed up.'

Key Takeaway

For facilities over 50,000 sq ft, in-house cleaning with factory-direct equipment almost always beats outsourced services on both cost and quality. The breakeven point is typically 3-6 months.