Innovaro Technology Delivers Cisco Meraki Network & VMware vSAN All-Flash Server Infrastructure for PFE’s New Head Office and Warehouse

Client Overview

PFE, a leading logistics and freight organisation, expanded operations with the construction of a major new warehouse facility in Witham, Essex. The new site required an enterprise-grade network capable of supporting high-density scanning devices, warehouse automation, office users, EV infrastructure, and mission-critical logistics applications.
 

PFE engaged Innovaro Technology to design, deliver, and document a fully resilient Cisco Meraki LAN and Wi-Fi 6E solution, along with a new VSAN server environment capable of supporting their growing operational workload. 
 

Project Background

PFE approached Innovaro seeking two comparative designs, one based on Cisco Meraki and a competing vendor solution.

After detailed workshops, heatmap simulations, and performance modelling, Innovaro demonstrated that Cisco Meraki provided significant operational advantages for warehousing environments, including:

• A wide range of Wi-Fi 6E access points to suit the project including models with integrated directional antennas, ideally suited for challenging warehouse deployment
• Simplified, unified cloud-based management of the wired and wireless networks for the PFE IT team
• Advanced network assurance capabilities to allow for faster issue remediation.
• Wireless capabilities including improved roaming experience with simplified deployment of standards like 802.11k/r/v
• Fully documented API to aid deployment and ongoing operation

In addition to the LAN and Wi-Fi project, Innovaro was further commissioned to deliver a replacement VMWare vSAN solution, ensuring high availability and performance for all virtualised workloads.


 

Objectives

Having selected Innovaro the main objectives for the project were:

• Deliver a fully resilient LAN and Wi-Fi 6 platform across a large warehouse and multi-floor office.
• Ensure full wireless coverage for handheld scanning devices, forklifts, automation equipment, and users.
• Implement a resilient VMware vSAN stretched cluster with All-Flash storage.
• Provide a design that supports business continuity, redundancy, and high performance.
• Deliver full documentation, handover, and testing — including predictive and post-deployment Wi-Fi heatmaps.
• Coordinate and manage the cabling partner to ensure the infrastructure met Innovaro’s design and quality standards.
   

Solution Overview 

Innovaro designed a complete end-to-end IT infrastructure built on Cisco Meraki’s cloud-managed ecosystem and VMware vSAN technology. The solution included: 

• Resilient collapsed core architecture, with 25Gb connectivity to the access switches
• 9 x IDF locations fed by dual-path OM4 fibre back to two resilient server rooms
• High-availability Cisco Meraki MX firewalls for resilient internet connectivity
• Cisco Catalyst 9300-M series switches managed by Meraki
• mGig capabilities supporting upto 5Gb/s connectivity for Wi-Fi 6E access points
• Cisco Meraki 9166D1 access points for warehouse, which reduced costs and complexity as due to integrated directional antennas
• Cisco Meraki 9164 access points for open plan areas and office floors
• Cisco Meraki 9163E outdoor access points to provide external coverage
• Highly available VMware vSAN All-Flash stretched cluster built on HPE ProLiant servers
• Eaton UPS solutions
   

Structured Cabling & Infrastructure Design with Octopus Cabling

Octopus Cabling (Colchester); a long-standing partner of Innovaro, made the initial introduction and were contracted to:

• Install and certify fibre optic cabling
• Install and certify Cat6A cabling for Wi-Fi access points
• Install and certify Cat6 cabling for user outlets
• Carry out installation of access points on behalf of Innovaro in a physically challenging environment

The cabling includes a 25-year manufacturer warranty, guaranteeing long-term performance and compliance.

Innovaro produced detailed documentation including:

• Full structured cabling layout
• Cabinet schematics
• Server room design for both core locations including collaboration with the M&E contractors
• IDF rack layouts and capacity plans
• Predictive modelling of wireless network in the warehouse, office and external areas
   

Cisco Meraki LAN & Wi-Fi 6E Deployment

The Cisco Meraki network was designed with high availability, speed, and resilience as core principles.
 

LAN Architecture

The Cisco Meraki Catalyst 9300 series switches were chosen for the project; these are highly performant cloud managed switches. The deployment included:

• Two core server rooms with matching collapsed core design
• 9 x IDFs located strategically around the warehouse
• Multi-mode OM4 fibre between each IDF and both core locations
• mGig capabilities to support Wi-Fi 6E data rates
• Cisco Meraki MX appliances deployed in a HA pair
• Stacking where appropriate for simplified management and resiliency
   

Wi-Fi 6E Deployment 

For the warehouse, Innovaro utilised the Cisco Meraki 9166D1 access points leveraging their integrated directional antennas which provided the following advantages

• Narrow beam pattern to suit installation at height above the warehouse racking supporting coverage along the long aisles
• Integrated directional antenna simplified mounting as there was no separate antenna to mount

The open-plan areas and office floors were covered using Cisco Meraki 9164 omni-directional access points with mGig connectivity at 2.5Gb. These were deployed to ensure exceptional user experience for line of business applications, collaboration tools etc, both today and long into the future.

For the external areas, IP67 rated Cisco Meraki 9163E access points with omni-directional antennas were deployed to provide coverage for devices in the yard and carpark including EV chargers to facilitate management and monitoring.
 

Post-Installation Wi-Fi Survey

Once the installation was complete, Innovaro carried out a full on-site post installation Wi-Fi survey to validate the solution matched the design requirements. This not only validates the design and implementation but allowed the team to tune the configuration to optimise for the complex warehouse environment. 
 

VMware vSAN Server Environment 

A VMware vSAN stretched cluster was deployed to deliver maximum uptime, fault tolerance, and performance for the warehouse environment to run mission-critical warehouse and business applications. Innovaro delivered:

• A resilient 8-node VMware vSAN all-flash stretched cluster built on HPE ProLiant servers
• High bandwidth connectivity to the new Cisco Meraki switches ensuring there is no bottle neck for the All-Flash vSAN solution
• Full documentation and testing of the VMware vSAN cluster
   

Project Delivery, Handover & Support 

As part of the project Innovaro provided:

• A dedicated project manager
• Engineering design workshops
• Full documentation packs
• As-built diagrams
• Post-deployment wireless survey for validation
• Knowledge transfer sessions
   

Results

The PFE Witham warehouse project has delivered significant operational and technical benefits, including:
 

Operational and Strategic Benefits

• 100% verified Wi-Fi coverage across aisles, offices, and external areas
• A resilient LAN, firewall, and VMware vSAN environment ensuring no single point of failure
• Simpler management, greater visibility and enhanced security thanks to the Cisco Meraki platform.
• Reduced IT operational risk due to the resilient network and VMware vSAN design
• A standardised and agile architecture that can be replicated and extended to support future growth
• All the Cisco Meraki hardware includes limited lifetime warranty helping reduce TCO 
   

Technical Achievements

• Full implementation of Wi-Fi 6E in a challenging warehouse environment
• HA Cisco Meraki MX design with multiple circuits for resilient connectivity
• Multi-gig switching enabling increased bandwidth for modern logistics systems
• VMware vSAN environment delivering high availability and future scalability
   

Installation & Quality Assurance

• All cabling completed by Octopus cabling to Innovaro’s design and professionally certified with a 25-year warranty
• Access point installation executed with precision using approved mounting solutions
• Extensive labelling and cable managemen
• Post-installation surveys verifying the solution delivered matched the design requirements
   

Client Testimonial 

“A project of this size and complexity presents challenges from time to time and Team Innovaro showed enormous dedication to overcome these and deliver a successful project. From start to finish, great projects guys!”

Richard Tewson - Head of IT, PFE
 

Conclusion 

Innovaro successfully delivered a resilient, scalable, and high-performance IT infrastructure for PFE’s new Essex warehouse. From structured cabling through to Wi-Fi 6E design, Cisco Meraki deployment, and VMware vSAN implementation, Innovaro ensured the environment meets the demanding operational requirements of a modern logistics facility.

Through expert engineering, documented best practices, and strong collaboration with Octopus Cabling, Innovaro has provided PFE with a future-ready platform capable of supporting growth, automation, and digital transformation for years to come.

The comprehensive 32-day programme ensured that every aspect; from system design and testing to live operation and post-event review was managed to the highest standard, solidifying Innovaro’s role as a trusted technology partner.