7 Best Racking Warehouse Systems: A Clear Explanation

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Best Racking Warehouse – A racking warehouse system is a storage solution that allows products to be stacked horizontally on many levels. These systems can aid in the management and better utilization of your warehouse space, as well as the organization of freight in order to streamline operations.

Each warehouse has its own set of standards. The ideal racking system should be able to maximize space utilization while minimizing disruption to your activities, particularly the picking process. Consider the following variables to determine which racking system is best for your warehouse:

Floor Utilization – A racking system’s ability to utilize warehouse floor space.
Budget – The approximated price per pallet. Consider this when ensuring that the racking system meets all of your requirements.
Forklift Accessibility – The ability to accommodate forklifts that are used to transport large goods. This takes into account the amount of aisle width that forklifts need to maneuver.
Storage Utilization – The quantity of space in the racking system that you can use. The amount you’ll require is determined by the volume, size, and weight of your shipment.
Inventory Management – The warehouse’s preferred order for inventory retrieval.
Versatility – The ability of racking systems to store a larger variety of items.

Inventory management is critical to simplifying warehouse operations in today’s fast-paced and highly competitive marketplaces. It’s one of the numerous difficulties that warehouse managers confront, but it can be mitigated by choosing the correct warehouse racking system. As a result, in this post, we’ll go over the best racking warehouse systems, as well as the elements to consider when choosing a good racking system and the many varieties.

To find out more about Warehouse Racking, please visit our Warehouse Racking for Sale pages, where you can also request a quote.

Best Racking Warehouse Systems Reviews

Selective Racking System

Pros & Cons

Pros

Because of the broader aisles and different access points, more than one forklift can be used.
Where the number of pallets per SKU is quite low
When you need unrestricted access to any pallet at any moment
When you need to pick from lower-level pallets
Can handle a variety of products.

Cons

It shouldn’t be used if you have a lot of pallets per SKU and are short on space, or if you need to pick from more pallets than the lower level pick face can handle.

Specifications

Budget	$45 – $65 per pallet
Floor Utilization	40%
Storage Utilization	90 – 95%
Inventory Management	First in, First Out (FIFO)

General Descriptions

Because of its low cost and wide range of sizes and attachments, the selective racking system is the most popular. This racking system is ideal for conventional storage for any application that requires quick access to materials.

Features

Supports First in First Out (FIFO)
Clear Aisles of 3 to 3.4m for reach trucks or 3.5 to 4.5m for counter-balanced forklifts.
Unfettered access to any pallet
The most common mode of racking
Storage Utilization: 90%, i.e. for every 100 pallet places available, you can fill 90.
Allows order picking at lower levels

Double-Deep Racking System

Pros & Cons

Pros

Forklifts with extendable forks are supported.
When you have a larger number of pallets per SKU
When you need a higher storage density
It’s ideal for holding items with the same SKU.

Cons

It should not be used when order picking from pallets is required, when pallets are regularly accessed for picking and then put away, or when you have a large number of SKUs with single pallets in stock.

Specifications

Budget	$50 – $70 per pallet
Floor Utilization	60%
Storage Utilization	85 – 90%
Inventory Management	First In, Last Out (FILO)

General Descriptions

The double deep racking system is a variation that provides a nice boost in density but necessitates specific equipment (extendable forks) and is more time-consuming to operate. It’s the best of both worlds: selective racking and high-density racking.

Features

FILO for each slot
Clear aisle of 3.0 to 3.4m
Need a forklift truck with extendable reach and camera to assist the operator
Pallets must be placed on beams at lower levels, and guide rails are employed at higher levels.
Reach and counterbalanced forklift tricks, as well as order picking devices, can be used to service them.
Typically, two pallets of the same SKU are placed in each double deep slot.
Storage utilization: 85-90%

Pallet Flow/Live Racking System

Pros & Cons

Pros

When you require FIFO, The stock and operation are moving at a relatively fast pace.
When each SKU has a large number of pallets
If you need a lot of space, this is the place to be.
It’s ideal for holding identical SKUs and high-volume commodities.
Supports forklifts

Cons

It should not be used if you have a small number of pallets per SKU, need to pick orders, can’t tolerate pallets colliding with each other due to line pressure, or can’t tolerate periodic snags caused by pallets stalling on the roll tracks.

Specifications

Budget	$170 – $185 per pallet
Floor Utilization	70 – 75%
Storage Utilization	85 – 90%
Inventory Management	First In, First Out (FIFO)

General Descriptions

Pallet flow racks are a type of high-density storage system that combines elevated rails with dynamic components like gravity rollers and conveyors. Gravity is used to power these warehouse storage racks. This racking system may increase or even quadruple your warehouse’s storage capacity, and it’s ideal for expiration-date-sensitive products.

Features

FIFO for each site
High use of cube
Clear aisle of 3.0 to 3.4m
Pallets are put on gravity roll rails and moved by gravitational attraction from entry to exit.
Separate load in and load out aisles
One lane per SKU
utilization: 85-90%
Full pallets only

Drive-In Racking System

Pros & Cons

Pros

Supports forklifts
When FILO is not a problem
When you don’t want SKUs to be mixed in each bay/lane of drive-in racking
When high-density storage is necessary (but keep in mind the honeycomb effect), which reduces the use
When high-density staging of received or chosen goods is necessary.
In each row, products cannot be mixed.

Cons

It should not be used if order picking from pallets is required or if you plan to use more than 60% of the available space.

Specifications

Budget	$160 – $185 per pallet
Floor Utilization	65%
Storage Utilization	60 – 65%
Inventory Management	Last In, First Out (LIFO)

General Descriptions

The drive-in racking system allows you to store products in your warehouse at maximum density. It eliminates aisles in a warehouse and is ideal for storing huge quantities of comparable products in a little amount of space.

Features

Clear Aisles of 3 to 3.4m for reach trucks or 3.5 to 4.5m for counter-balanced forklifts
Can be up to 10 or 12 pallets deep and up 6 or 7 pallets high
FILO for each lane
To deposit or pick up pallets, the forklift travels down the lane of each racking bay.
Drive-in racking resembles the process of block stacking, but there is less damage to pallets and stacking can be higher with the racking.
Utilization: 50-60%

Push Back Racking System

Pros & Cons

Pros

It’s ideal for holding items with the same SKU.
When you need to increase storage density and have more pallets per SKU
When order pickup from pallets within push back racking is not necessary
Supports forklifts

Cons

It should not be utilized when order picking from pallets is required, when pallets are accessed regularly for picking and subsequently put away, or when pallet to palate contact can result in stock damage.

Specifications

Budget	$275 – $295 per pallet
Floor Utilization	75%
Storage Utilization	75%
Inventory Management	Last In, First Out (LIFO)

General Descriptions

The push-back pallet racking system provides greater pallet storage while also improving selectivity by using separate lanes for each SKU, making them easier to locate, pick, and put away. Push back warehouse storage racks remove the requirement for multiple aisles by allowing for front-loading and unloading.

Features

Clear aisles of 3 to 3.4m
It can be three or four pallets deep, but most are simply two.
Forklift trucks push pallets back from the aisle.
Pallets are loaded into carts with a reduced friction surface.
Only used to store complete pallets.
To avoid pallet damage, forklift drivers must be cautious when loading in and out.
Utilization: 85-90%

Narrow Aisle Racking System

Pros & Cons

Pros

It is possible to store a wide range of objects.
When you have a large number of SKUs with small quantities per SKU
Wherever you want to get the most out of your space
When a big number of products is being moved in and out,
When you wish to increase your warehouse’s storage density,

Cons

Inaccessible by standard forklift; requires articulated or turret trucks.
It should not be used if you can’t afford to run two machines at the same time, if your budget is limited, or if you have a high movement velocity and require two machines to work in the same aisle at the same time.

Specifications

Budget	$50 – $60 per pallet
Floor Utilization	90%
Storage Utilization	95%
Inventory Management	First In, First Out (FIFO)

General Descriptions

Narrow aisle racking is similar to selective racking in that it provides easier access to each pallet. The warehouse storage racks use floor space and roof height to create high-density storage.

Features

Clear aisle of 1.8 to 2.2m
Only one machine in an aisle at a time
Simulates the effects of selective racking.
At the end of each bay of racking, turret trucks retrieve and place pallets from pick and deposit (P&D) stations.
Turret trucks need wire or mechanical direction down each aisle’s length.
Pallets are delivered and picked up by a separate forklift to and from the P&D stations.
Picking from pallets is possible for order picking machines although not at the same time as turret trucks.
Utilization: 90%

Steel King SK3000® Structural Rack

Pros & Cons

Pros

Modular system allows design flexibility
Expands easily
Thicker and tighter fitting connector plates
All structural

Cons

Not mentioned

Specifications

Frame Bracing	Braces are 1.5” x 1.5”
Beams	Manufactured with high-strength steel
Connections	2” adjustability for better space utilization

General Descriptions

Because it is made of strong C-channel structural steel, Steel King’s SK3000 pallet racking by Prologis Essentials delivers increased overall strength and stiffness. The SK3000 is a high-performing material handling rack and the greatest value in structural pallet racks today, with a longer service life, fewer maintenance costs, and greater safety. The SK3000 Structural Rack is a modular system that can be configured to accommodate a range of applications and quickly extends as per your needs.

Upright frame columns come in three sizes: 3′′, 4′′, and 5′′. The use of structural channel steel allows for increased resistance to forklift impact damage while also boosting load bearing capacity and seismic resilience. The whole horizontal and diagonal bracing uses structural angle. High-strength steel beams are one-piece, seamless, and continuously welded with a complete vertical weld. Bolted beams may be adjusted in 2′′ vertical increments with ease.

A thick 7 gauge wrap-around connector plate is used for column-to-beam connections, which helps square the rack for a tighter connection. When compared to single bolt systems, using two bolts per beam gives 57 percent higher strength. Your system’s shear strength is improved with Grade 5 hardware. The bolted connectors are built to RMI specifications.

The strength of SK3000 can be seen from top to bottom. Standard footpads are welded to each column and are comprised of 7 gauge steel plates, effectively distributing floor stresses. There’s also a footpad that’s more durable. Powder coating is not only more attractive, but it is also more resistant to impact damage, chemicals, chips, and scratches than liquid coating.

FAQs about Racking Warehouse Systems

Why Should We Use a Warehouse Racking System?

For one thing, using a racking system is far less expensive than doubling the size of an existing warehouse. Adding a racking system to your warehouse can double or even triple the number of goods you can handle, and adding forklifts to a simple warehousing operation usually results in a significant increase in efficiency.

Businesses nowadays are more concerned with the bottom line than ever before, and a warehouse without even the most basic racking system is nearly always inefficient. Forklifts are generally present in warehouses that deal with large commodities, making the transfer to a racking system much easier.

What Safety Concerns Are We Looking At?

You’ll need to take extra special precautions to avoid damage because your raw materials will be stored dozens of feet above the warehouse floor. Pay strict attention to any slack racking system components, especially after installation, because even the smallest mistake could result in materials falling.

Also, make sure to adhere to each manufacturer’s rigorous load limitations. While your racking system may appear to be capable of handling more, it is not safe and could result in goods being damaged or workers being injured. Rack audits should be conducted regularly to maintain product integrity.

What is a Concentrated Point Load?

The weight of a concentrated static load is not equally distributed throughout the deck’s surface. A point load is a static load that is concentrated at certain locations on the deck. For example, a container with feet or bars that hold the weight, which is concentrated in a few different regions of the container, could be used.

How Often Should We Have My Racks Inspected?

MHI (Material Handling Institute) recommends having your racks evaluated at least once a year. Additionally, if a forklift or other warehouse equipment damages your racking system, we recommend having your racks inspected replacing the damaged item. In your warehouse, safety should be a top priority.

Why Do My Racks Need to be Anchored?

Racking must be attached to the floor, according to the Rack Manufacturers’ Institute. This is true for all racking frames at all times. Contact the manufacturer if you’re not sure what size anchor bolts to use. If you’re in a seismic zone, you may need more than a conventional ½” anchor bolt to meet the requirements.

You may only require one anchor bolt per column, or you may need to utilize all four holes in the base, depending on the racks and your position. Your manufacturer should be well-versed in the regulations and can ensure that your racks are properly grounded to comply with local regulations. Anchors maintain the racks in place, ensuring pallet racking reliability and durability while also ensuring warehouse safety.

Conclusion

Due to the huge range of racking systems available on the market, choosing the best racking warehouse systems can be a difficult undertaking. Considering the elements described above is the best method to prevent becoming overwhelmed with this activity. The ideal warehouse racking system will help you make the most of your space while also streamlining your warehouse processes.

Call today to speak with one of our Material Handling Service Providers on Linquip if you are ready to automate inventory management or are searching for a solution to boost efficiency, or if you have another question about pallet racking or any other warehouse equipment or services.