What Are the Different Racking Systems Used in Storage Facilities ?

Racking systems help storage places keep things neat. They also save space and make work faster. Pallet racking systems can let a warehouse hold 40% more than just stacking on the floor. The main types are pallet racks, shelving for small things, and special racks for different items.

Key Takeaways

• Pallet racking systems help store more items and make work faster by keeping things neat and saving space.

• Different racking types work for different jobs: selective racks let you reach items easily, drive-in racks save space for big groups of items, and pallet flow racks help move perishable goods first with FIFO rotation.

• Picking the right racking system depends on how much inventory you have, what kind of products you store, your warehouse size, and how often you move things to keep work safe and productive.

Types of Racking Systems

Pallet Racking Systems

Pallet racking systems are very important in most warehouses. These systems have upright frames and beams to hold pallets. Adjustable pallet racking is flexible. Workers can move the beams up or down. This helps fit different pallet sizes or products. Businesses like adjustable pallet racking when their inventory changes a lot.

There are many kinds of pallet rack systems. Some are selective, double deep, drive-in, and pallet flow racks. Each kind helps with different storage needs. Selective pallet racking lets workers reach every pallet fast. This is good for products that move quickly. Double deep pallet racks store more but are harder to reach. Drive-in and drive-through racks are best for lots of the same items.

Static pallet racking has shelves that do not move. It is good for heavy or long-term storage. Dynamic pallet racking uses gravity or rollers to move goods. Dynamic racks, like pallet flow racks, save space and make picking faster. Compact racks, such as mobile or stack racks, help save space and change as needed.

Pros:

• Adjustable pallet racking is flexible and easy to change.

• Compact racking stores more and saves space.

• Pallet rack systems work for many industries, like retail and healthcare.

Cons:

• Some pallet racking needs special tools or training.

• Compact racking can make it hard to reach some pallets.

• Dynamic racks can cost more to set up and keep working.

Typical Applications:

• Warehouses and distribution centers

• Cold storage for food and medicine

• Manufacturing plants for materials and finished goods

Pallet Racking Types

Modern warehouses use different pallet racking types to keep goods organized. These racks help workers do their jobs faster and save space. The table below shows the most common types and how they are used in 2024:

Tip: Pallet racking is used in over 61% of racking setups worldwide. This makes it the main system for most warehouse storage.

Selective Pallet Racking

Selective pallet rack systems are the most popular for many warehouses. This system uses upright frames and beams to make shelves for pallets. Workers can reach every pallet without moving others. This makes it good for places with many SKUs and lots of picking.

Main Features:

• Direct access to each pallet

• Adjustable pallet racking beams for different pallet sizes

• Supports both FIFO and LIFO inventory management

• Compatible with standard forklifts

Pros:

• High selectivity and flexibility

• Cost-effective for most warehouses

• Easy to install and reconfigure

Cons:

• Lower storage density due to required aisles

• Not ideal for bulk storage of similar items

Best Use Scenarios:

• Warehouses with high SKU counts

• Cold storage, retail, and manufacturing

• Operations needing frequent access to diverse products

Note: Selective pallet rack systems are the best pallet racking system for warehouses that need fast access and quick inventory changes.

Double Deep Pallet Racking

Double deep pallet racking lets you store two pallets in each shelf spot. This system saves aisle space and can hold up to 40% more than selective racking. But to get the back pallet, you must move the front one, so it uses LIFO.

Main Features:

• Two pallets deep per shelf

• Requires special reach trucks with telescopic forks

• Adjustable pallet racking design for changing needs

Pros:

• Higher storage density than selective racking

• Good for storing large volumes of similar SKUs

• Cost per pallet similar to standard racking

Cons:

• Lower selectivity; slower access to rear pallets

• Needs specialized equipment and operator training

Best Use Scenarios:

• Warehouses with limited floor space and high volumes of similar products

• Facilities with sufficient ceiling height and unobstructed lanes

Double deep pallet racking is great for businesses that want to use more space but still need some access to their goods.

Drive-In & Drive-Thru Racking

Drive-in racking and drive-thru racking help save space by using fewer aisles. Forklifts drive into the racks to load or take out pallets.

Drive-In Racking:

• Pallets are stored in lanes several positions deep

• Operates on a LIFO system (last-in, first-out)

• Ideal for storing large quantities of the same product

Drive-Thru Racking:

• Similar structure but allows access from both ends

• Supports FIFO inventory management

Better for warehouses with diverse SKUs

Pros:

• Maximizes storage density

• Reduces aisle space

• Cost-effective for bulk storage

Cons:

• Limited selectivity, especially for drive-in racking

• Higher risk of pallet damage

• Slower loading/unloading for specific pallets

Best Use Scenarios:

• Cold storage, food and beverage, and bulk goods warehouses

• Facilities with homogeneous inventory and high turnover

Push Back Racking

Push back racking uses carts on slanted rails. When you add a new pallet, it pushes the others back. This system works on LIFO and can hold two to six pallets deep in each lane.

Main Features:

• Single aisle access

• Pallets move forward automatically when one is removed

• Moderate selectivity

Pros:

• Higher storage density than selective racking

• Reduces aisle requirements

• Good for high-volume, non-date-sensitive products

Cons:

• More expensive than selective racking

• Not suitable for FIFO inventory

• Limited to uniform pallet sizes

Best Use Scenarios:

• Urban warehouses with high rent

• Facilities storing similar products in large quantities

Push back racking gives a good mix of storage space and easy access. It is a smart choice for warehouses with little room.

Pallet Flow Racking

Pallet flow racking, or live pallet racking, uses gravity rollers to move pallets from the loading side to the picking side. This system uses FIFO and can store up to 20 pallets deep in each lane.

Main Features:

• Gravity-driven movement

• Dedicated loading and picking aisles

• High-density storage

Pros:

• Maximizes storage capacity, nearly doubling inventory in the same footprint

• Reduces labor and equipment costs

• Improves inventory control for perishable goods

• No electrical power required

Cons:

• Higher upfront cost

• Lower selectivity; limited access points

Best Use Scenarios:

• Food and beverage, pharmaceuticals, and high-turnover products

• Warehouses needing strict FIFO inventory control

Live pallet racking systems help move goods quickly and cut down on mistakes. They are great for fast-moving, date-sensitive items.

Cantilever Racking

Cantilever racking is made for long, bulky, or odd-shaped items that do not fit in regular racks. This system uses arms that stick out from a center post, so there are no front columns.

Main Features:

• Open front for easy loading and unloading

• Adjustable arms for different item sizes

• Supports heavy and long items

Pros:

• Easier access for bulky or long items

• Flexible for various product lengths

• Sturdy and durable for heavy loads

Cons:

• Requires wider aisles

• Less dense than other pallet racking types

• Specialized equipment may be needed

Best Use Scenarios:

• Lumber yards, metal fabrication, and furniture warehouses

• Storage of pipes, steel bars, carpet rolls, and large furniture

Cantilever racking is best for things like lumber, pipes, and big furniture.

Mobile Racking

Mobile racking systems put racks on rails so they can move and open aisles only when needed. This system gets rid of fixed aisles and uses space better.

Main Features:

• Racks move on tracks to open access aisles

• Controlled manually or automatically

• Adjustable pallet racking options for changing needs

Pros:

• Increases storage capacity by 50-80%

• Maximizes space utilization in small warehouses

• Supports automation and high-density storage

Cons:

• Higher initial investment

• Requires flat, even floors for rail installation

• May slow access if multiple aisles are needed at once

Best Use Scenarios:

• Cold storage, archives, and urban warehouses

• Facilities with limited space and high storage needs

Mobile racking systems help businesses double or triple storage in the same area. They are a smart pick for growing companies.

Carton Flow Racking

Carton flow racking, a type of live pallet racking, uses gravity rollers or wheels to move cartons from the loading side to the picking side. This system is perfect for small boxes and high-volume picking.

Main Features:

• Gravity-fed lanes for cartons or totes

• Rear loading and front picking

• Supports FIFO inventory management

Pros:

• Reduces pick paths by up to 65%

• Improves picking speed and accuracy

• Enhances ergonomics and safety

Cons:

• Not suitable for heavy or oversized items

• Higher cost than static shelving

Best Use Scenarios:

• E-commerce, distribution centers, and retail warehouses

• Operations needing fast, accurate order picking

Carton flow racking makes picking and restocking faster and easier. It is a key part of efficient warehouse racking systems.

Warehouse racking can help with many storage needs. Some racks are good for fast picking. Others, like pallet flow racks, work well for items that move quickly.

• Look at how big and heavy your inventory is.

• Think about how often you move items in and out.

• Check the size and shape of your warehouse.

• Pick racking systems that fit how often you pick items and keep things safe.

Tip: Picking the right racking system for a small warehouse helps you work better and stay safe.

To get the best results, think about how your business might grow. Choose a racking system that can change as your inventory changes.

FAQ

What is the safest racking system for heavy loads?

Selective pallet racking systems hold heavy things safely. They give strong support and help stop accidents. This keeps workers safe in the warehouse.

How does mobile racking save warehouse space?

Mobile racking systems move racks on rails in small warehouses. Only one aisle opens at a time. This setup lets you store more things in less space.

Which racking system works best for cold storage?

Pallet flow racking systems keep products moving in cold storage. They use gravity rollers to move items forward. This helps use first-in, first-out inventory rotation.