Understanding Pallet Racking Systems: Types, Benefits, and Considerations

The vast majority of warehouses and distribution centres organise the distribution of their storage by installing pallet racking. The racking designed to store pallets optimises the available space and adapts to each company’s storage needs. This article delves into the different types of pallet racking systems that can be installed in a warehouse, outlining their characteristics, differences, and key considerations.

What is Pallet Racking?

Pallet racking is a storage system designed to organise goods on pallets or other auxiliary elements, creating a unit load that facilitates their storage and transport through different phases of the supply chain. This system emerged during the Second World War to optimise transport, initially utilising wood for manufacturing. Today, pallet racking is predominantly made from metal and designed to handle heavy loads, ensuring that warehouse operations are efficient and safe.

Major Advantages of Pallet Racking

Pallet racking systems offer several advantages that contribute to the efficiency and safety of warehouse operations:

Optimised Loading and Unloading Times: Streamlined processes for moving goods in and out of storage.
Better Utilisation of Space: Compact storage solutions that make the best use of available warehouse space.
Enhanced Safety: Secure storage systems that protect products during transport and handling.
Flexibility in Handling: Versatile storage systems that accommodate different types of goods and pallets.
Simplified Inventory Control: Easier tracking and management of stock.
Cost Reduction: Lower handling, transport, and storage costs due to efficient space utilisation and streamlined processes.

Selective vs. Compact Systems

When choosing a pallet racking system, companies must evaluate their specific storage needs and constraints. The decision often boils down to selecting between selective storage systems (offering direct access) and compact storage systems (designed to maximise storage density).

Selective Storage Systems: Ideal for warehouses where quick and easy access to all unit loads is a priority. These systems require a larger surface area but offer direct and fast access to stored goods.
Compact Storage Systems: Best suited for warehouses with limited space or high floor costs. These systems increase storage density, optimising the available space, but may compromise direct access to individual unit loads.

Types of Pallet Racking Systems

There are several types of pallet racking systems, each with unique features and benefits. Here, we explore the main types of pallet racking available for warehouses.

1. Adjustable Pallet Racking

This is the most common and simplest pallet racking system. It involves mechanically storing pallets using forklifts that operate parallel to the rows of racking. Although it requires a wide surface area, it offers direct and quick access to all stored unit loads, along with versatility and adaptability.

2. Very Narrow Aisle (VNA) Racking

VNA pallet racking is an adaptation of the adjustable pallet racking system, designed to make better use of the available warehouse space. The work aisles are narrower, reducing the necessary floor space while maintaining direct access to all pallets. Special narrow aisle forklifts are required to navigate these aisles.

3. Double Deep Pallet Racking

This system modifies the adjustable pallet racking by adding an extra position for pallets at the back of the racking, effectively storing unit loads at two depths. This increases storage capacity but reduces selectivity, as direct access to every unit load is not possible.

4. Drive-In and Drive-Through Compact Systems

These high-density systems eliminate work aisles, allowing forklifts to enter the racking structure for loading and unloading.

Drive-In Racking: Operates on the Last-In, First-Out (LIFO) principle with a single entry and exit aisle.
Drive-Through Racking: Uses the First-In, First-Out (FIFO) principle, featuring separate aisles for loading and unloading.

5. Live Storage for Pallets (FIFO)

FIFO Live Storage Pallet Racking includes a compact structure with roller lines on a downward incline, moving pallets from the loading point to the retrieval end. This system ensures perfect stock rotation by following the FIFO principle.

6. Push-Back Pallet Racking

Similar to FIFO live storage, but operating on the LIFO principle. When a new pallet is loaded, it pushes the previous pallet back. This system uses rollers or trolleys to facilitate the movement of pallets.

7. Mobile Pallet Racking

In this system, racking structures are installed on chassis guided by floor rails, enabling lateral displacement of racking modules. It is a compact structure allowing work aisles to be opened as needed for forklift operations.

Components and Considerations

Pallet racking systems consist of several key components, including frames, cross beams, and accessories like wire decking, post protectors, safety panels, and row spacers. Understanding these components is crucial for selecting the right system.

Frames and Uprights: Vertical columns supporting the racking system, with holes for adjusting shelf height.
Cross Beams: Horizontal elements connecting frames, creating shelves for pallets.
Wire Decking: Enhances safety and stability by providing a larger surface area for pallets.
Post Protectors and Safety Panels: Protect the structure and stored goods from damage.
Row Spacers and Wall Ties: Maintain alignment and stability of the racking system.

Choosing the Right Pallet Racking System

Selecting the appropriate pallet racking system involves considering several factors:

Storage Density: How much space is needed for storing goods.
Warehouse Layout: The design and available space within the warehouse.
Inventory Management: How frequently stock is rotated and accessed.
Load Requirements: The weight and size of the goods to be stored.
Cost: Budget for purchasing and installing the racking system.

Conclusion

Pallet racking systems are essential for optimising warehouse operations, ensuring efficient storage, and facilitating easy access to goods. With various types of pallet racking systems available, each offering unique benefits and suited to different needs, companies can find a solution that fits their specific requirements. By understanding the characteristics and advantages of each system, businesses can make informed decisions to enhance their storage capabilities and streamline their supply chain operations.