Different Types Of Pallet Racking Systems

The convenience of pallet racking is their use of otherwise wasted vertical space, which maximizes a warehouse’s storage space. There are numerous pallet racking types, each offering a slightly different layout to suit various needs.

This guide reviews pallet racking systems: what they are, how to choose the perfect option, and all the different options.

So continue reading for all the details you will ever need on pallet racking systems and the various types!

What Is A Pallet Racking System?

Pallet racking systems are a type of material storage system specifically designed to handle items on pallets. They make use of otherwise unused vertical space. The pallets, which are filled with inventory, sit on horizontal rows in several vertical sections.

Warehouses often use pallet racking to optimize the use of their space. Employees use forklift trucks to load and unload materials on the rack shelves. Integrating this system into a warehouse environment saves stock-picking time and increases warehouse efficiency.

How To Choose The Right Pallet Racking For Your Warehouse

The process of choosing a pallet racking system for your warehouse depends on several of your operation’s key factors. Your budget, the space you are working with, how you want to store items, and what you are storing are all critical factors.

Consider the warehouse layout and what types of pallet racking may work for your business. Many warehouses employ various kinds of racking systems in the same facility. Here are a few questions to outline the requirements of your operation:

-What are the warehouse’s product flow requirements?

-Are the products stored on pallets, or will you need individual piece picking?

-Does there need to be specific areas for picking and overflow storage?

-What amount of space is available (floor and vertical space)?

-Can pallet racking easily secure to your floor?

-Will the warehouse need a forklift to load, unload, or access products?

-Will you need cooling or freezing capabilities?

Ensure Pallet Rack Security Cage Enclosure

Pallet racking security cages help protect products perched on the shelves. The rigid welded wire prevents products from falling, thus ensuring the safety and security of warehouse employees and the product themselves. Additionally, a fully enclosed pallet rack prevents theft of anything stored on the rack.

Custom pallet rack security cage enclosures are available through various companies. However, many companies make standard-sized panels to match the beam length in width. Companies use a variety of wiring, some using ten gauge welded wire, while others use six gauge welded wire. The panels attach to the rack with mounting brackets and come as sliding or double hinged doors.

At The Safety Source, we can provide and install whatever option you want.

10 Most Common Types Of Pallet Racking System For Warehouse Storage

There are ten primary types of pallet racking systems, each serving a similar purpose, just in a slightly different way.

Some of the most common types of pallet racking systems include:

Selective Racking Mode

Selective racking is ideal for scenarios with a relatively low number of pallets per SKU. This type of racking is the most common among various applications. Selective racking supports first-in, first-out (FIFO), allows access to any pallet, and has a storage utilization rate of 90%.

It isn’t the best choice for space-restricted warehouses with a high number of pallets per SKU. Additionally, this type of racking isn’t ideal for warehouses that need to pick from more pallets than the lower level pick face will facilitate.

Price: $46 to $60 per pallet

Push Back Racking Mode

Push-back racking boosts storage density, as it provides 85 to 90% storage utilization and is suitable for situations with more pallets per SKU. This type of racking is often two pallets deep, but it can be up to four pallets deep. It supports first in, last out (FILO) in each slot and is used for whole pallet storage only.

Push back racking mode isn’t for situations where order picking from the pallets is necessary or when pallets are regularly accessed for picking then returned to their original spot. Forklift drivers need to be very careful not to damage the pallets during loading in and out. Due to this, push-back racking isn’t the best choice for where pallet to pallet contact could result in damage to stock.

Price: $275 to $295 per pallet

Double Deep Racking Mode

Like push-back racking, double deep racking supports FILO in each slot. Double deep racking supports storage utilization of 85 to 90%. It is ideal for warehouses with more pallets per SKU and when higher storage density is required. It’s typically used for two pallets in the same SKU in the same double deep slot.

Double-deep pallet racking systems aren’t ideal for warehouses that regularly perform order picking from the pallets or those that routinely access pallets for picking then put them away again.

Price: $55 to $65 per pallet

Pallet Live Storage Mode

Pallet live storage systems operate using gravity roll racks that move pallets down the line via gravitational pull. They support FIFO for each lane and require separate load in and out aisles. Pallet live storage racks utilize 85 to 90% of spaces.

This type of racking is great for warehouses that need FIFO operation and cycle through stock quickly or have a high number of pallets per SKU. However, it isn’t the best choice for those with very few pallets per SKU, need to perform order picking, or cannot have pallets encountering others due to line pressure.

Price: $400 to $420 per pallet

Drive-in Racking Mode

Drive-in racking systems are ideal for high storage density requirements and where FILO doesn’t pose an issue. These systems can stretch up to 7 pallets high or 12 pallets deep. They only provide 50 to 60% space utilization, making them unsuitable for warehouses needing greater space utilization.

Price: $165 to $180 per pallet

Narrow Aisle Racking Mode (Turret Truck)

Narrow aisle racking is ideal for warehouses needing good space utilization and hasmany a large number of goods cycling through, as it provides 90% space utilization. Turret trucks, which require wire or mechanical guidance, are necessary for putting pallets away from pick and deposit stations at the end of each bay.

Since this type of racking requires turret trucks and a separate forklift, it isn’t the best choice for warehouses that cannot afford to have two machines operating. Additionally, narrow aisle racking isn’t for warehouses requiring high movement velocity with two machines simultaneously working in the same space.

Price: $50 to $60 per pallet

Narrow Aisle Racking Mode (Articulated Reach Truck)

Similar to the other narrow aisle racking mode, the primary difference of this option falls to the difference in accessing pallets. Articulated reach trucks can maneuver from truck unloading to rack without the assistance of P&D stations or guidance. This racking system utilizes 90% of the space.

Narrow aisle racking, accessible via articulated reach trucks, is a good option for high SKUs with small quantities per SKU. However, this option isn’t good for warehouses with high movement velocity and requires two machines working simultaneously in the same aisle.

Price: $60 to $60 per pallet

Mobile Racking Mode

Mobile racking systems are suitable for warehouses with a high amount of storage, as it supports 90% storage utilization but modest pallet movement. A single aisle opens at a time, allowing access to pallets. Many warehouses use mobile racking for cool or cold stores.

Mobile racking isn’t the best choice when frequent carton picking is necessary or when employees need to operate in more than one aisle at a time.

Price: $700 to $800 per pallet

Satellite Racking Mode

Also known as deep-lane pallet racking, satellite racking is ideal for a high volume of products shifting through each SKU. It’s commonly used to overcome poor space utilization with other options, such as drive-in racking, and utilizes 90 to 95% of space. Satellite racking may have up to 40 pallets in length per lane, which are accessible via a remotely controlled mobile shuttle.

This type of racking is not the best choice for warehouses that regularly need to pick from the pallets. The mobile shuttle costs about $50,000, so it isn’t a budget-friendly option.

Price: $185 to $250 per pallet

High Rise Racking Mode

Serving as a high-density storage system, high-rise racking utilizes between 90 and 95% of space. Automated cranes typically service the system, which may be single or several pallets deep. This racking mode is excellent for warehouses with limited space and a high volume of products cycling through the system.

High-rise racking requires a dedicated building and isn’t budget-friendly. Given its accessibility by cranes, it isn’t ideal for warehouses that need to pick from pallets.

Price: $350 to $400 per pallet, plus building costs of $950 to $1,000/sqm

Conclusion

Pallet racking systems are an excellent alternative to other storage options that require excessive floor space. The pallet racking storage system that is ideal for your warehouse depends entirely on the situation, including your budget, the area you’re working with, and the needs of your warehouse.

With the abundance of choices, businesses can find the option that will best suit the needs of their warehouse. However, it can be a challenging task to find the right system. That is why our crew at The Safety Source is here to help– contact us today for all your pallet racking needs.