What is a warehouse racking system?

Warehouse racking systems (also called pallet rack systems) are storage systems used in most warehouses to hold inventory.

Warehouse racking systems consist of several warehouse racks, which are industrial shelving units made of metal designed to store boxes or pallets in multiple levels of horizontal rows, stacked on top of each other.

What are racking systems used for in warehouses?

Businesses use racking systems to optimize their warehouse storage. Racking systems can double or triple your warehouse’s inventory holding capacity without increasing the square footage you pay for, making them a cost-effective solution for small businesses looking to maximize their warehousing storage space.

A rack system also helps keep inventory organized, as it provides a dedicated storage space for each SKU. For fast-growing companies transitioning away from haphazard garage storage, steel shelving racks with storage bins or pallets can improve inventory management, and make it easier to find and pick units.

Warehouse Racking Types

There are several types of warehouse racking systems, which also are known as pallet racks or materials handling systems. Wooden, metal, or plastic pallets, or skids, are combined with larger racking systems comprised of shelves at various levels. Decking bases are available in different widths to support objects placed on the racks in storage. In many cases, warehouse racking is several feet high and requires forklifts for the loading process. Various warehouse racking system configurations are possible including selective racks, drive-in or drive-through racks, push-back racks, and flow racks.

• Selective Racks – The most commonly used pallet system, selective racks provide access from an aisle. These warehouse racking systems are ideal for narrow aisle racking, standard systems, and deep-reach systems. Selective racks require special narrow lift trucks and accommodate a single pallet in depth
• Drive-In and Drive-Through Racks – For high-density storage, drive-in racks and drive-through racks are ideal. Constructed of steel in most cases, these warehouse racking systems have enough space for a forklift to move into its bay. It’s important to note that drive-in racks have one entrance and exit, but drive-through racks allow access on both sides of the bay. As a result, drive-in racks are suited to the last in, first out (LIFO) process commonly used for nonperishable products or those with a low turnover. On the other hand, a drive-through system requires a first in, first out (FIFO) process. Drive-in and drive-through racks may be floor-to-ceiling structures
• Push Back Racking Systems – Typically used for bulk storage, push back racking systems store products that span 2-5 pallets. When a pallet is loaded onto the system, it pushes the next pallet back, and when a pallet is unloaded, it is pushed to the front of the system. Push-back racking systems utilize the LIFO system and often feature inclined rails and sliding carts and double lanes
• Flow Racks – Also known as gravity racks, flow racks are commonly used for high-density storage. With this type of warehouse racking system, items are loaded at the higher end and removed at the lower end using a FIFO system. The rotation of products becomes automatic as the racks flow with loading and unloading. Flow racks make use of gravity rollers that move in conjunction with the rack load and feature brakes or speed controllers to regulate item movement. One advantage of flow racks is they do not require electricity for operation because gravity powers them 

There are different methods for storing products, from stacking pallets on the floor to using adjustable pallet racking or more advanced storage systems. The various types of industrial storage systems enable far more efficient storage management by making the most of the available space and facilitating other logistics tasks associated with inventory management.

In a warehouse or distribution centre that manages multiple products, it is best to store each type of goods with the most appropriate storage system. The choice of this will depend on variables such as the characteristics of the goods, their dimensions and their rotation.

We review below the different types of storage systems, and their main advantages and characteristics.

 

What are industrial storage systems?

A storage system is designed to optimise the arrangement of goods or products on racking or structures, to make the most of the available space. This approach allows a greater number of products to be stored in reduced areas and heights, improving space efficiency. The racking systems are separate structures to the building, although they can be fixed to its structure using floor, wall or ceiling anchors. This structural independence ensures greater flexibility and adaptability in the organisation of the warehouse.

Racking can be classified in various ways, but one of the simplest is to divide it into two categories: direct access racking and compact racking. Direct access racking provides complete access to each unit of goods, facilitating storage, retrieval and order preparation tasks. This category is ideal for warehouses that handle a wide variety of products and require immediate accessibility.

By contrast, compact racking is designed to maximise space efficiency, allowing greater storage capacity over a particular area. This type of racking is especially useful in situations where space is limited and storage density is a priority.

The choice between direct access racking and compact racking will depend on a company’s specific needs, considering factors such as product variety, frequency of access to goods and space limitations.