For most companies, space is a volatile resource. Seasonality and growth are the culprits that cause most managers to evaluate their space restrictions constantly. In this article, I hope to familiarize an aspiring owner or manager looking to optimize vertical space in their warehouse with pallet racking.
Storing pallets on the floor? Double/triple stacking damaging product?
Delivering most products requires palletizing, putting a product on a pallet for easy mobility. Once palletized, new companies typically store their pallets on the floor and, if possible, stack palletized products on top of each other. But, stacking pallets on top of each other is not always feasible. Some products are asymmetrical, and it would be dangerous to stack pallets and have them balanced. Also, if the palletized product is too heavy, it could cause damage by crushing the product or pallet near the bottom of the stack. Pallet racking can solve both problems with ease and simultaneously organize your facility.
There are various options when it comes to pallet racking. There are companies that specialize in creating complete custom racking solutions that perfectly fit your needs. Unfortunately, most small to mid-sized companies can’t afford these solutions and are left with more standardized options. You’ll likely have to use a standard pallet to use these standard options.
Rack for the pallet, or pallet for the rack?
The most commonly used pallet is a 48x40-inch GMA pallet. Since the 48x40 pallet is widely used, it also is sold at an affordable price. Most bulk pallet racking is built for this size and thus has a lower price than other custom solutions. If your product allows it, engineer the palletization process to fit a 48x40-inch footprint. Consult with your pallet provider to ensure the pallet’s weight capacity fits your application.
Again, racking can be tailored to pallets of any size. If you have a very specialized product or significant space restrictions, it might be more beneficial to buy custom racking. If custom racking is already purchased, consult with your pallet provider to purchase custom pallets that will more efficiently match your product and your processes.
In some cases, not all products can be stored in a racking system because they are hazardous for insurance purposes or fire code regulations.
Here are four common racking solutions that satisfy most customer needs:
Selective Pallet Racking
Drive-In Pallet Racking
Pallet Flow Rack System
Push Back Pallet Rack
Selective Pallet Racking
Selective pallet racking is the most common pallet racking available. Selective racking employs upright structures and two cross beams that create a shelf to store the pallet. You can get additional cross beams to make as many shelves as needed (depending on the height of your ceiling and the weight of your product). Here’s a link for more information. A structure that has a 42-inch depth is perfect for a 48x40-inch pallet.
Drive-In Pallet Racking
Drive-in pallet racking allows forklifts to drive directly into the racking to store and retrieve products behind one another. The racking has ridges on the sides that hold the pallets while allowing a forklift to drive through. This system can be set up in many ways to utilize FIFO (First In, First Out) or LIFO (Last In, First Out) inventory management strategies. This solution optimizes space by permitting dense storage.
For this application, it’s important to have thick deck boards on your pallet. As opposed to Selective racking, the deck boards carry the most stress from the product's weight. Also, certain-size forklifts may be required to fit between the aisles.
Click here for more information and pictures.
Pallet Flow Rack System
Pallet flow racking is similar to drive-in racking in terms of storage density. Instead of driving into the storage, the pallets are loaded from the back onto gravity rollers pitched slightly towards the front, where they are unloaded. This system utilizes the FIFO inventory management. It’s easy for the operators because moving material doesn’t require driving deep into racking aisles.
Click here for more information and pictures.
Push Back Pallet Rack
A push-back pallet rack operates exactly like the pallet flow rack system, except it does not get loaded from the back. Pallets are loaded and unloaded from the front of the racking. Gravity rollers are still pitched downwards, and the product is moved further into storage as items are added. This system utilizes LIFO inventory management.
Click here for more information and pictures (and a good video).
Summary
There are many different pallet racking options. Evaluate your current storage situation, determine the flexibility of your pallet requirements, and decide on your rack solution, and you’ll be ready to start optimizing space and storage!