Hi Roger, welcome to the list!

Is there any possibility of adding open shelving for un-boxed file
storage at your facility?  Clearly there would be an investment in
equipment, but it will solve the issue of having to re-box over time.
You might want to see if you can estimate the average linear inch growth
of an HR file (.25 inches/year/folder?  More?  Less?) so you can
properly forecast the amount of shelving you'll need to accommodate
files over their full retention period.

Another option is to contract with a 3rd party storage facility that
already provides this service.

As for budgeting, see if you can shift some of the burden to the HR
department by setting them up as an internal client so they "pay" you
for your services/space/equipment, etc. (a standard "charge back"
scenario).  If you go there, be prepared to develop service level
agreements that detail what you will do, what they should expect, how
much it will cost them and perhaps a service maximum on the volume of
material you will handle at the negotiated price.

Just a few quick thoughts.  Good luck!

Julie

Julie J. Colgan
Manager of Records Services
Arnall Golden Gregory LLP
171 17th Street NW
Suite 2100
Atlanta, GA 30363
404.873.8164 direct
404.439.1811 fax
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