If you’re wondering “What is pallet racking?”, then this article is definitely for you! Pallet racking is a storage solution that arranges pallets of items in rows on metal shelves with several levels accessible to forklifts or cranes. This technique maximizes vertical space utilization, much like skyscrapers in cities, to enhance storage density effectively.
The use of pallet racking systems offers various advantages. They improve convenience by providing quick access to stored items, supporting various load weights, and requiring little maintenance. Plus, they’re inexpensive, long-lasing, and facilitates clear floor space, resulting in safer and more maneuverable warehouses.
This article digs further into the notion of pallet racking by walking readers like you through the many pallet racking types. Understanding these systems allows firms to better optimize their storage solutions, eventually enhancing efficiency and allowing future expansions.
What Is Selective Pallet Racking?
Regarding pallet racking systems, it would be remiss if this guide forgets to talk about their most popular type: selective pallet racks. They are specifically designed to provide effortless access to every pallet. By using the single-depth concept, employees can access on both sides of the aisles, making inventory management a breeze.
Selective pallet racking systems stand out for their incredible versatility. They can easily handle a wide range of pallet dimensions and types, making them a perfect fit for any warehouse’s unique requirements.
Opt for selective pallet racks if you require regular access to all stored items in your inventory. It’s also ideal for warehouses that handle a diverse range of products and experience frequent turnover.
PROs:
- Offering instant access to each pallet from both sides of the aisles.
- Simple to install and reconfigure.
- Extremely flexible when it comes to accommodating various pallet sizes.
- Being the most popular racking variant in the market.
CON:
- Demanding additional aisle space, thus resulting in lowered storage density.
What Is A Drive-In Pallet Rack?
The following pallet racking type enables forklifts to access and exit the structure via its single aisle, thereby facilitating the seamless retrieval or placement of pallets. By utilizing a LIFO (last-in, first-out) method, drive-in pallet racks maximize storage space by eliminating the need for multiple aisles.
This storage system consists of one or more multi-tiered racking lanes, each of which is generally three to five pallets deep, accessible from the front, and assigned to a certain product only. Because each lane is exclusively accessible from the front, forklifts can handle pallets in a single work aisle.
That feature is what makes drive-in racks unique. Their design eliminates all wasted footprint and therefore offers exceptional inventory capacity. The storage solution can hold large quantities of similar products, especially bulk storage and seasonal goods. Drive-in racks are also effective in environments with low turnover rates.
PROs:
- Optimizing storage capacity to its fullest potential.
- Minimizing the requirement for aisles.
- Perfect for large-scale inventory demands.
CON:
- Limiting accessibility to individual pallets due to the LIFO system.
What Is A Teardrop Pallet Rack?
What makes teardrop pallet racks special is the unique inverted hole shaped like a teardrop, which is used to attach shelf beams without the need for additional tools. This feature is also the reason why people call this storage system the teardrop pallet rack.
Widely popular in North America thanks to the exceptional flexibility and user-friendly design, teardrop racks utilize roll-formed steel for their beams and uprights. The cherry on top is that their form allows you to incorporate new racks into existing ones without completely redoing everything.
In addition to the easy installation, teardrop racks are also simple to adjust and reconfigure. Depending on your inventory demands, you can add to this pallet racking system various pallet racking accessories, such as wire decking, row spacers, cross bars, and anchors.
PROs:
- Requiring no tools for installation and reconfiguration.
- Highly adaptable to changing inventory needs.
- Compatible with numerous accessories for additional features.
CON:
- Not as robust and durable when compared to other pallet racking systems
What Is A Double-Deep Pallet Rack?
As the name suggests, double-deep pallet racks allow two pallets to be stored in each rack, thereby effectively doubling storage capacity compared to the typical single-depth systems. However, you’ll need a forklift with extended reach to access the back pallets.
A major strength of double-deep racks is their affordable prices compared to other complex racking systems. Yet, the solution doesn’t offer direct access to all pallets and is only suitable for the LIFO approach.
So, for those who want to optimize their inventory capacity while ensuring sufficient access to products, consider using double-deep pallet racks. These storage solutions work fine with items with a moderate turnover rate.
PROs:
- Doubling inventory capacity with the unique design.
- Optimizing warehouse space utilization.
- Well-suited for medium-turnover products.
CON:
- Requiring special forklifts with deep reach capabilities.
What Is A Shuttle Pallet Rack?
Unlike the aforementioned solutions, which aim to balance between storage capacity and product accessibility, shuttle pallet racks utilize automated shuttles to efficiently transport pallets within the racking system, significantly reducing the need for forklift travel. This also saves a lot of time and manual efforts while handling objects.
Although shuttle pallet racks are somewhat pricey, with certain models valued as high as 50,000 USD, they are suited to both the LIFO and FIFO configurations. That’s the reason why this racking variant is a superior option to aforementioned systems.
The automation of this system greatly enhances the efficiency of loading and unloading processes. Therefore, it’s a great solution for large warehouses with high throughput demands. You’ll most likely see shuttle pallet racks in industries that require swift operations, such as food and beverage.
PROs:
- Automating pallet transportations for increased efficiency.
- Optimizing forklift travel time.
- Facilitating high storage density.
- Well-suited for both the FIFO and LIFO stock management methods.
CON:
- Needing higher upfront investments.
What Is A Mobile Pallet Rack?
This inventory solution features chassis rails added to the warehouse floor, allowing racks to move from side to side. This characteristic offers top-notch flexibility to create aisles whenever necessary. By eliminating the need for multiple permanent aisles, this solution significantly increases storage density.
For instance, suppose you have three racking blocks: block 1, block 2, and block 3. If you wish to retrieve items objects from block 1, just move block 2 over to open up the room for your forklifts to enter and complete the task.
Thanks to the unique mobility feature, mobile pallet racks are perfect for cold storage or other inventory settings with limited space. They also offer easy access to your required items. And while you’re loading or retrieving those products, other commodities become inaccessible, which they’re better safeguarded.
PROs:
- Offering flexible access to stored products.
- Highly space-saving, thus well-suited for compact facilities.
- Perfect for temperature-controlled inventory settings.
CON:
- Rendering slower access to commodities due to movable racks.
What Is A Very Narrow Aisle Pallet Rack?
During your search for the ideal pallet racking system, if you stumble upon the term “VNA”, you’re looking at “Very Narrow Aisle” pallet racks. These solutions feature much narrower aisles compared to conventional racking systems. This helps optimize storage capacity without the need for warehouse expansion.
Besides, this inventory solution offers significant versatility with height-adjustable beams to accommodate various sorts of stored items. It’s also a reasonably priced option for many warehouses. However, the tight spaces of this system requires the use of specialized forklifts equipped with guided systems.
A good practice is to employ VNA pallet racks in situations where there is limited space but high storage capacity is needed. Also, remember that this storage system only allows one operating forklift at a time.
PROs:
- Utilizing limited warehouse space efficiently.
- Allowing for manual product pick-up on lower rack levels.
- Favored by many warehouses thanks to the system’s competitive price.
- Excellent for items that are frequently sold or used.
CON:
- Relatively more costly due to the required use of specialized forklifts.
What Is A Push-back Pallet Rack?
With the use of inclined rails, the push-back system allows for easy addition of new pallets by simply pushing back the existing ones. During the loading phase, the newly loaded pallet will take the front spot, pushing all following pallets to the rear of the structure. While emptying the first pallet, the whole row of pallets will move ahead.
Therefore, this inventory solution operates on a LIFO basis, where pallets are automatically advanced when one is taken out. What makes push-back pallet racks a huge hit is their impressive capacity to store multiple pallets deep, while ensuring convenient access to the front pallet.
If you’re looking for a storage solution that can effectively and densely house multiple pallets of the same commodities, consider using push-back pallet racks. They’re true saviors for warehouses that experience moderate to high levels of activity.
PROs:
- Optimizing inventory capacity.
- Providing effortless accessibility to the front pallets.
- Highly effective when dealing with similar items.
- Facilitating faster product pickup.
CON:
- Only suitable for the LIFO inventory management.
What Is A Gravity Pallet Rack?
Also known as flow racking, gravity pallet racks utilize inclined wheels or rollers with centrifugal brakes to effortlessly transport pallets using the force of gravity. Pallets are placed on one side of the structure and removed from the other. With the removal of each pallet, the next one instantly takes its place.
Although gravity pallet racks are seemingly similar to the push-back system, they actually have some distinguishing features. One of them is that it’s compatible with the FIFO (first-in, first-out) approach. Moreover, gravity racks allows for exceptionally high-density storage, with a single aisle capable of housing up to 20 pallets.
The gravity-fed mechanism of this storage system ensures smooth stock rotation and effortless access to items. For that reason, it’s a recommended option for perishable goods or items that have expiration dates, such as medicines, food, and beverages.
PROs:
- Reducing product handling time.
- Implementing the FIFO stock rotation precisely.
- Perfect for perishable items.
CON:
- Requiring precise assembly to guarantee optimal function.
Best Practices When Using Pallet Racking Systems
As promised, after exploring various configurations of pallet racks, it’s time to share essential practices during your use of these inventory systems. Failing to follow these activities properly can lead to disastrous outcomes for your warehouses.
#1: Avoiding Overloading At All Costs
Complying to pallet racking weight limitations is critical as overloading can cause rack collapses. These occurrences endanger warehouse staff and damage commodities. Not to mention, consistently ignoring weight limitations reduces the pallet racking system’s longevity, resulting in expensive replacements and downtime.
To avoid overloading, always remind employees of these load restraints by showing weight indicators clearly for each rack in the warehouse. This guarantees that personnel load and unload appropriately, thereby minimizing dangers. Another useful practice is to reserve the rack’s bottom half for larger items, and ensure the system can handle them.
#2: Establishing Appropriate Load Distribution
Besides paying attention to weight limitations, you’ll also need to ensure proper load distribution of pallet racking systems. Uneven weight distribution may weaken the structure, leading to rack failures. Similarly, these events put your employees at risk, damage stored items, and disrupt warehouse operations.
To achieve this pointer, rotate your stock on a regular basis to minimize uneven loads and long-term stress on certain racking portions. Plus, it’s important to spread the weight equally between the storage solutions. These two tips help maintain structural integrity and minimize accidents, resulting in a neater and more secure warehouse.
#3: Maintaining Easy Accessibility
Cluttered aisles restrict accessibility from vehicles like forklifts and pose trip hazards for warehouse employees. Therefore, regularly clean the passageways surrounding pallet racking systems. This practice not only provides easier access during emergencies but also facilitates a safer working environment.
Moreover, when constructing pallet racks, avoid positioning these solutions against walls to allow maximum accessibility. It’s efficient to maintain equal aisle widths on both racking sides, so that warehouse inspectors and forklifts can reach the storage solutions with ease.
#4: Training Staff Of Correct Product Handling Procedures
Proper training guarantees that the warehouse staff adhere to safe procedures, hence reducing accidents. Among the various training points, it’s crucial to regularly train and remind employees of correct product handling procedures.
Specifically, before transferring pallets, forklifts operators should inspect them for damage. Slow, consistent loading improves control and reaction time. Plus, pallets must be centered on beams to avoid beam deflection and racking collapses.
Another important point is to let pallets overhang beams slightly in order for forklift drivers to see them safely. This prevents pallets from being pushed too far or not far enough.
#5: Adding Safety Gears For The Racks
Investing in and maintaining safety equipment displays a commitment to a safe warehouse. You can consider a few options below to not only minimize accidents but also facilitate a secure inventory facility:
- Pallet rack guards: These tools help prevent damage from probable collisions, most likely from forklifts. They serve as the first line of defense against mishaps and human errors.
- Locks: If you need to control who can access the inventory space and who cannot, you must install locks to pallet racking systems. Locks guarantee that only authorized individuals can reach the structures, thereby lowering the danger of thieves.
- Upright protectors: Besides the function of safeguarding pallet racks against forklift collisions, upright protectors also help retain the structural integrity.
- Safety pins: Despite their small sizes, safety pins play an incredibly important role. Once installed, they keep beams in place and prevent them from moving unintentionally.
Conclusion
If you’ve made it this far, it’s pretty sure that you can confidently answer “What is pallet racking?” now. Each variety, from selective to gravity pallet racks, has a distinct design and application customized to specific demands, which helps increase efficiency and storage capacity.
Businesses can make educated judgments that meet their unique inventory needs by researching the advantages and disadvantages of different pallet racking systems. Drive-in racks, teardrop racks, and double-deep racks all provide significant benefits for efficient material handling.
This detailed guide attempts to demystify the pallet racking concept by providing best practices and insights into its various forms. Implementing the correct pallet racking system can transform warehouse management as it improves organization, increases storage capacity, and prepares for future growth.
