To compete in a rapidly-changing business environment, warehouses and distribution centres are constantly looking for ways to gain an edge. Regardless of which part of the business gets optimized, an increase in efficiency and productivity seems to be the common thread. For companies trying to reduce waste, lean management or Just-in-Time techniques are implemented. Those trying to increase picking accuracy, may deploy technology like a Screen-to-Voice solution. Businesses trying to increase storage space may install multi-story mezzanines.

Whether its a high-tech or a low-tech solution, if the basics are not in place, there is little hope of it having the desired impact on the business. One common piece of equipment in every warehouse is racking of some kind. But from years of optimizing for clients, we find they often don’t have the best fit for the SKU carried.

With the basic ‘building block’ of warehouse storage already wrong, pickers whether human, robot, or voice-assisted simply can’t reach the goods on time. This can snowball into missed deadlines and customer dissatisfaction.

Pallet racks are synonymous with storage; but how many can tell the difference between them? At first glance, a rack is just a rack, right? It shouldn’t matter how goods are stored, right? Wrong. The extra seconds added per trip per picker quickly adds up and manifests as missed deadlines and lost man-hours.

Here is a look at the most common pallet racking systems and our recommended best use for them:

Selective pallet racking – This is the most common racking system in the world, due to its versatility and relatively low cost. The system makes it easy to rotate stock, it offers maximum accessibility to goods and direct access to all pallets. Individual pallets and palletised goods can be easily located and moved allowing rapid handling and fast turnaround. It also allows access to every pallet, allowing pickers pick from pallets directly on the ground or on shelving beams.

Best Use: In warehouses that carry a wide range of stock on pallets.

 

Drive-in pallet racking – High density pallet storage is achieved here by storing pallets in lanes several pallets deep and several pallets high. The pallets are driven into the rack system by the forklifts and loaded on the rails. It’s known as drive-in if the rack system is placed against a wall or closed at one end of the system. If it is located in an open area, and the forklift can drive through the system, it’s referred to as drive-thru racking.

Best Use: In warehouses where block stacking isn’t encouraged due to the risk of product crushing.

 

PushBack Racking – These store pallets on wheeled carts that move along rails in the rack frame. By utilizing a slight tilt of the rails, gravity makes the carts roll towards the load or unloading end of the rack where forklift operators can load/unload pallets. Because forklifts operate in independent lanes/aisles, pushback pallet storage also offers a more versatile storage option than drive-in racking. The trucks never enter the rack system, thus reducing the chance of an acident occuring.

Best Use: For storing SKUs with multiple pallets.

 

Carton Flow Storage – This is an ideal solution for fast moving products as it provides quick and easy access to all items. The gravity driven system allows SKUs to be loaded from the back and flow to the front (pick face). This allows accurate First In First Out (FIFO) picking and means no stock remains on the shelf till its out of date. It can also be used in tough storage conditions such as cold rooms.

Best Use: For SKUs that need 100% stock rotation.

 

Double deep racking – This is ideal for warehouses that distribute high volumes of the same product. By storing pallets two-deep, this system allows for greater storage density using only half the of aisles required.

Best Use: In warehouses where goods must be picked on a FIFO or LIFO basis.

 

Cantilever Racks – Coming into the Christmas season, these will be used to store Christmas trees and other long, bulky items. They are also common in industries and warehouses where a wide variety of shapes and lengths of materials need to be stored. Because there are no front columns on cantilever racks, loading and unloading of the racking is quick and efficient.

Best Use: For storing heavy long materials, think lengths of steel, timber, 20 foot Christmas trees etc.

 

These are six of the most common racking configurations available today. They can also be combined to form larger, more complex structures, depending on individual needs.

Are you still storing your fast moving goods on selective pallet racking? While its a passable option, it’s not the best option for efficiency. Pickers will have to walk longer distances to retrieve SKUs, when they could have been placed on a carton flow rack, and have gravity do part of the work for you.

For more optimization tips, contact Monarch Limited today and let us find a storage system that will work for your business. Monarch Limited is also known for offering very durable industrial storage products, from racks, mezzanines to bins. For excellent deals on new and used equipment, call us today.