Finding the right storage system or a mix of systems is crucial for the efficient operation of your warehouse or distribution center and ensuring all products and materials are neatly stored away for safety and easy access. Because there is a bevy of warehouse storage equipment to choose from, it’s best to consider the different types of warehouse storage systems before considering changes or a new layout.
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Storage Cabinets
Storage cabinets are one of the most basic types of warehouse storage systems, ideal for storing away a large volume of small items. The size of the cabinets and storage capacities can be tailored to the size of the materials and products your warehouse stores away. A benefit of using storage cabinets is that they can be modified for greater efficiency by using partitions. Partitions allow smaller materials to be stacked alongside lengthier or larger materials. While cabinets may seem limiting in comparison to some of the other systems we’ll touch on, it’s worth noting that cabinets are perfect if you need to ensure the materials are protected from external conditions or need extra security.
Static Shelving
Static shelves are similar to storage cabinets in that they are fixed to a particular location. The ability to adjust the heights of the shelves allows you to formulate a layout that’s beneficial to your warehouse’s efficiency particularly if it’s dependent on locating stock-keeping units (SKUs) quickly.
If locating your SKUs quickly isn’t your top concern, the primary benefit of static shelving is that they’re the most stable despite being a simple design. The simple structure allows for the other static shelves to be built in close proximity to each other so that a warehouse can optimize its space and increase efficiency.
Mobile Shelving
In contrast to static shelving, mobile shelving contains opportunities for higher storage capabilities. For mobile shelving, the shelving is affixed to a track that allows for fewer aisles and ensures each rack is more easily accessed. When it’s built for mobility, the structure of the shelving is supported by sturdy conventional components like decks and bracing that stabilize and support the chassis that allows the storage structures to move along the tracks.
Pallet Racking
For warehouses that find themselves with large quantities of standard inventory, pallet racking should be your first choice. Racking is designed to take advantage of floor and vertical air space. Pallet Racking is considered to be flexible and easy to fit into any space that you have. To get the most out of this system you will need to carefully plan how it will be best organized to accommodate your material flow process and what your density requirements will be.
Dynamic Storage
Also known as “Forward Pick”, dynamic storage systems are intended for the section of the warehouse where the items are consistently used to fulfill your orders. In this area, high selectivity and density storage are crucial. To this end, there are a few options to choose from that will improve accessibility.
- Push-Back Rack. This system ensures no space is wasted. When product is added, prior inventory is pushed back to reduce honeycombing and empty pick faces. The store inventory is kept neatly organized while remaining easy to reach from the aisle.
- Pallet Flow. Using a combination of elevated rails and components like wheels, conveyors, or rollers, pallet flow makes use of gravity to improve rack-supported structures. Pallets are loaded in the back and move towards the front through the force of gravity. As you unload one pallet, another will move into its place and be ready for unloading.
- Drive-In. This solution is designed for high-density storage. This system maximizes your warehouse’s space and height by reducing the forklift operating aisles. You’ll often find this the most popular method of storage for warehouses with a homogenous inventory of products.
Double-Deep Racking
Sometimes a warehouse must handle a high-volume inventory while only having so much space. In this scenario, the most efficient system is typically double-deep racking. This is when standard-sized pallets are placed back-to-back to, essentially, create double-sided shelving.
When using double-deep racking, it’s typically accompanied by a “last in, first out” inventory system. This means it’s not the most ideal system for perishable inventories. Instead, consider this system for inventories of clothes, appliances, electronics.
Double-deep racking is helpful for inventory management that prioritizes SKU’s according to their value. Goods that accrue in value over time are capable of safely being stored away in a double-deep racking system but increase the chance of your warehouse becoming overcapacity.
Automated Storage and Retrieval Systems (AS/RS)
Automation is becoming increasingly more common as delivery demands rise and customer expectations increase. Automated Storage and Retrieval Systems (AS/RS) can quickly improve the efficiency of a warehouse by eliminating the travel time of forklifts and time required to locate and retrieve specific products. AS/RS systems are best utilized for high throughput scenarios, heavier inventory loads and high-volume processing for limited number of SKU’s. AS/RS systems increase space for storage by reducing aisle spacing traditionally accommodating lift trucks.
AS/RS systems when integrated with WMS/WEX are instrumental in inventory management and improving order accuracy and above all reducing possible safety hazards.
Mezzanine Work Platforms
Mezzanines and work platforms add instant usable floorspace to your warehouse by using air space for storage, picking or other value-added activities. When relocating is not an option or your location limits your ability to build on, adding a mezzanine or platform can provide immediate benefits.
In order to choose the most efficient system for your warehouse, visualizing the future and your growth plans is key. Anticipating future needs will ensure your chosen system will accommodate your immediate needs and have the flexibility and capacity to grow with your business
Pallet racks are metal structures designed to support the goods in a warehouse or an industrial facility. Various factors, such as the type of products, order of inventory retrieval, space/cost limitations, and turnaround time, can impact the selection of a rack type.
Selecting the type of rack to use in your warehouse can be challenging. A well-designed warehouse pallet racking system can help optimize available space and throughput while ensuring operational productivity and safety.
This article will explore the key differences between industrial rack systems, highlighting the pros and cons of each type. Whether you are in the market for a new rack system or simply looking to understand the available options better, this article will provide valuable insights into the world of rack types.
Static vs. Dynamic Racking Systems
There are two main categories of racking systems commonly used in warehouses: static and dynamic. Each category has several types of systems. Each type of racking system has unique advantages and disadvantages, and understanding these differences can help you select the best racking system for your specific needs.
In this blog, eight types of racking systems will be discussed:
Static pallet racks
Dynamic pallet racks
Static Racking Systems
A static pallet racking system is built to be stationary (pallets do not move once put in place or retrieved). Static racking systems are commonly used due to their adjustability and typically have lower costs than dynamic systems.
Static racks include selective (single-deep), double-deep, cantilever, and drive-in/drive-through pallet racks.
1. Selective Racks (Single-Deep)
Selective (single-deep) pallet racks are the most commonly used pallet rack systems in warehouses. They are cost-efficient and the least expensive compared to other rack types. These racks offer adjustability and are an ideal option for storing different kinds of products.
Figure 1: Selective rack (single-deep)
The rack’s beam heights and bay widths can be adjusted to meet the requirements of various sizes and weights of pallets. They are often configured in back-to-back rows to conserve aisle space.
Advantages:
- Inexpensive compared to other rack types.
- Immediate access to all storage locations.
- Easy to modify (engineering approval required).
Disadvantages:
- Apart from setups with very narrow aisles (VNA), not very dense as they require multiple aisles.
- Costly for high-volume storage; many racks and ample warehouse space required.
2. Double-Deep Racks
Double-deep racking systems are similar to selective (single-deep) racking systems in their core components, but they have a key difference: they feature an added second row. This design enhances storage capacity, making it suitable for items with high inventory levels.
Figures 2 and 3: Double-deep rack (side and top view)
Double-deep racks are mainly used for cold storage to maximize space and cost or dry storage where expiry is not a concern. This racking requires a specialized deep-reach forklift truck for loading and unloading due to its two-load-depth configuration.
Figure 4: Back-to-back double-deep racks
Advantages:
- Compared to single-deep racking systems, double-deep racks have increased storage density.
- Cost efficient – Fewer aisles while allowing more storage capacity at a lower cost.
Disadvantages:
- Require deep-reach forklift trucks to access pallets on the second row.
- Reduced accessibility – Access to rear pallets becomes more challenging, as it requires moving the front pallets first, leading to slower inventory retrieval times.
3. Cantilever Racks
Cantilever racks are specialized racks providing a space-efficient storage solution for long and bulky items, like PVC pipes, steel sheets, and lumber. They are constructed from vertical columns, braces, arms, and bases. Depending on their design, cantilever racks can be used for light to heavy-duty applications.
Figure 5: Cantilever rack
Cantilever racks are assembled in two possible configurations: single or double-sided. Single-sided racking is only accessible from one side and is typically built against a wall. Double-sided racks provide direct pick access from both aisles, back-to-back, where the same column is used with arms on both sides. These racks are frequently found in plumbing supply warehouses, lumber yards, and shipping yards.
Advantages:
- Ideal for storage of long/bulky loads
- Variable storage capacity, from light to heavy-duty products.
- Quick storage and easy retrieval of products.
Disadvantages:
- High capital cost compared to other storage racks.
- Considerable floor space required for safe forklift access.
Are you interested in learning more about heavy duty cantilever racks? Contact us today to secure an expert consultation!
Explore more:
What is Cantilever? Cantilever & Lumber Racks Explained
4. & 5. Drive-In and Drive-Through Racks
Drive-in and drive-through (sometimes called drive-thru) rack systems offer high-density storage capacity by maximizing warehouse space. These racks are called “drive-in/through” because forklifts must drive directly into the rack structure to access and place pallets on the rails that span the depth of the structure.
Drive-in pallet racks have a single entry and exit point on one side of an aisle. Drive-thru racks have an entry and exit point on opposite ends of the system, allowing forklifts to enter the rack structure from the front or the back.
Drive-in and drive-through bays are often arranged side-by-side to maximize the warehouse floor space and height, and each bay-level depth can hold multiple pallets. Considering the high storage capacity it provides, it is a highly cost-effective racking system compared to the other racks.
Figure 6: Drive-in rack
A drive-in rack system operates in LIFO (last in, first out) stock rotation: the last pallet deposited in a slot will be the first to be unloaded. Since the forklift has one access point for each aisle for loading/unloading the pallets, you can install the rack against a wall. Due to its low rotation, this system is common in cold storage units and freezers.
By contrast, a drive-through rack system operates in FIFO (first in, first out) stock rotation: the first pallet deposited on the racking will be the first to be unloaded. The forklift can access both ends of the aisle, one for loading and another for unloading. The racks must be installed in the warehouse aisles, not against a wall.
Figure 7: Drive-through rack
Advantages:
- Warehouse space optimization.
- Cost-effective, high-density rack systems.
- Significantly less square footage required compared to selective pallet racks.
Disadvantages:
- Not ideal for facilities with many different products.
- Prone to damage since forklifts enter the rack.
- Not flexible in design; standard pallet sizes required.
Dynamic Racking Systems
There are two types of dynamic rack systems: gravity racks and mobile racks. Gravity pallet racks, either Push Back or Pallet Flow, are designed with levels on an incline, and the racks are resting on wheeled carts or rollers. Mobile racks are selective single-deep racks mounted on wheels. They operate using a motorized unit, which allows the rack’s rows to be moved on slab-level rails.
1. Push-Back Racks
A push-back racking system is a high-density storage system with a stock rotation method similar to a drive-in racking system: LIFO (last in, first out). The main difference is that the pallets are loaded onto a gravity-fed wheeled cart system that rolls on an inclined rail in each lane. The forklift has one access point for each location for loading/unloading pallets.
Figure 8: Push-back rack
To load, place a pallet on a rolling cart. The cart is then pushed back into the system each time an additional pallet is loaded. Due to the incline, the carts roll down to the aisle position and are held in place by the structure when a pallet is removed. The incline makes this rack system significantly faster to load and unload than a drive-in rack system.
Advantages:
- High-density storage capacity.
- Lower rack damage because forklifts do not enter rack structures.
Disadvantages:
- Costly compared to a drive-in pallet rack system.
- Higher maintenance and lifetime service costs for the rolling cart system.
2. Pallet Flow Racks
Pallet flow racking is a high-density storage system with pallets on roller conveyors. The stock is rotated on a FIFO (first in, first out) basis, similar to a drive-through rack system. The difference is that pallet flow racks are operated on an inclined gravity-induced roller system, and the forklifts cannot enter the racking system.
Figure 9: Pallet flow rack
Pallet flow racking systems have forklift access at two ends of the system, one for loading and the other for unloading. The pallets are loaded onto rollers at one end, which are moved by gravity to the front of the system for easy unloading.
Advantages:
- Increased worker productivity - reduced travel time to load/unload.
- Quick inventory turnover through FIFO (first in, first out).
Disadvantages:
- High initial capital investment.
- Regular maintenance of the braking system.
- Pallets must always be in good condition to prevent jams.
Carton flow racks are essentially pallet flow racks, but they are used for picking up small boxes instead of pallets. They are mostly integrated with selective racks to create a dynamic hybrid system to support both pallets on the upper levels and picking on the bottom levels. Both carton flow and pallet flow racks share functionality but serve different purposes.
Figure 10: Carton flow rack
3. Mobile Racks
Mobile racking is a compact storage rack on a rail system attached to the floor. The racks are on wheels that move along the floor rails and are aligned with each other to save space.
Figures 11 and 12: Mobile racks
Adjacent rows are moved using a motorized unit to access an aisle. It is possible to incorporate various safety features (such as audible or visual alarms) into the system to minimize risks of collapse and workplace incidents. Mobile racking is an ideal storage solution in situations with space restrictions.
Advantage:
- Space-efficient since it requires less space than selective racking.
Disadvantages:
- High installation and maintenance costs.
- Typically requires increased safety measures.
- Additional time required to move rows before accessing pallets.
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Comparison of all industrial rack types
The table below compares all the rack types discussed based on different selection criteria.
In conclusion, pallet rack systems are a crucial component in warehouse storage and organization of goods. There are several categories and types of pallet rack systems, each with its unique advantages and disadvantages and best suited for specific merchandise and storage needs.
Carefully choose the right pallet racking system for your warehouse needs. Products, warehouse space, and cost should be considered when making your selection. With the right pallet racks in place, you can create an effective warehousing system and improve the productivity of your warehouse.
Remember that regardless of the type of racks you choose, they must always be in safe working condition. To assist with this, Damotech offers a variety of free tools that can help you assess the condition of your racking systems and identify any potential hazards. By utilizing these resources, you can take the necessary steps to ensure that your pallet racks are safe and reliable for your employees and your business.
If you are looking for more details, kindly visit mold rack.
Content References
- https://www.srs-i.com/blog/advantages-disadvantages-cantilever-racking/
- https://www.mazzellacompanies.com/learning-center/warehouse-racking-pallet-rack-systems-different-types-design/
- https://www.mskcanada.com/en/blog/5-advantages-of-high-density-industrial-mobile-shelving
- https://www.super-racking.com/info/advantages-and-disadvantages-of-mobile-shelves-51912413.html
- https://mallardmfg.com/pallet-flow-racking-vs-simple-selective-pallet-rack-when-why
- https://www.ar-racking.com/en/news-and-blog/storage-solutions/storage-racking-solutions/types-of-industrial-racking-for-the-warehouse-classification-and-characteristics
- https://arnoldmachinerymh.com/pallet-racking/push-back/
- https://www.warehousestoragesolutions.com/push-back-pallet-racking-what-is-it
- https://www.commander.ca/product-push-back-pallet-racking/
- https://gujratsteel.com/advantages-and-disadvantages-of-drive-in-racking-systems/
- https://www.ar-racking.com/en/news-and-blog/storage-solutions/storage-racking-solutions/differences-between-drive-in-and-drive-through-racking
- https://www.ar-racking.com/en/news-and-blog/storage-solutions/storage-racking-solutions/types-of-industrial-racking-for-the-warehouse-classification-and-characteristics
- https://ecseco.com/blog/single-vs-double-deep-selective-rack-which-is-the-best-option-for-you/
- https://phindustry.com/2016/08/07/top-benefits-of-single-deep-pallet-racking/
- https://vestrainet.weebly.com/blog/selective-racking-advantages-and-disadvantages
- https://advancestorageproducts.com/4-advantages-to-utilizing-double-deep-selective-pallet-racking-in-your-warehouse
- https://www.mskcanada.com/en/blog/5-advantages-of-high-density-industrial-mobile-shelving
- https://ecseco.com/blog/stackable-racking-types-and-use-cases/
Figure References
- Figure 7: https://www.cssyes.com/product/twinlode-drive-in-pallet-rack/
- Figure 10: http://3dlogistic.ca/carton-flow/
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