Racking systems: types and how to choose them - Interlake Mecalux

Identifying and installing the right racking system for your warehouse operations can make the difference between optimal logistics performance and bottlenecks. You’ll find a wide variety of industrial racks in today’s market. The ones produced by top manufacturers undergo testing and simulations, comply with regulations, follow the strictest safety controls, and incorporate high-quality raw materials.

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What is a racking system?

A racking system consists of several modules with shelves used to store industrial products and other types of items on pallets or in boxes or bins. The racks are typically made of metal and play a crucial role in facilities like warehouses and logistics or production centers.

Unlike wooden structures, metal rack storage systems withstand intensive use and facilitate material handling. Therefore, they’re compatible with material handling equipment such as forklifts, typically employed to store and remove pallets from the racks.

Advantages of racking systems

Incorporating racking systems into your operations to raise competitiveness brings multiple benefits, for example:

• Inventory control. Well-organized storage systems streamline operations. They allow for better tracking, from receiving to order fulfillment and shipping.
• Increased storage density. Compact racking systems concentrate large amounts of materials in the same available space.
• Space utilization. Floor space is limited, and purchasing logistics real estate can be costly. Thus, designing a well-organized warehouse layout with the right racking systems or automated storage and retrieval systems (AS/RSs) is more cost-effective.

How do I choose a racking system?

Using the appropriate equipment for each task is essential for ensuring warehouse efficiency. As a result, racking systems vary greatly depending on a company’s sector and activity. Your end goal in selecting a racking system for your business is to save time and money during operations. These are some factors to take into account:

• Characteristics of boxes or pallets. Knowing the size, shape, quantity, and weight of the unit load that best fits your inventory is vital for choosing the perfect racking system.
• Warehouse layout. In addition to the available square footage of floor space, it’s fundamental to consider the height of your facility. This factor can be decisive for its capacity to carry out large or small operations.
• Accessibility. Operators must be able to reach pallets and materials quickly and efficiently.
• Budget. Consider which option will be more cost-effective in the long term. Some might require a more hefty initial investment but deliver a generous return and superior strength and durability.

To make the right choice, it’s advisable to rely on storage experts and familiarize yourself with the main types of racking systems.

Types of racking systems

Racking systems can be grouped into three major categories: pallet racks, shelving, and other racking solutions.

Pallet racks

With pallet rack systems, loads are stored and removed using forklifts. They can provide direct access to each pallet or function as a high-density solution.

• Selective pallet racks. These offer direct access to every SKU in the warehouse. They’re the most universal storage solution thanks to their versatility and are suitable for companies with very varied SKUs.
• Drive-in drive-thru pallet racks. This is the simplest and most affordable high-density system. It consists of racks with lanes accessed by forklifts to deposit and retrieve pallets at several levels and depths. With drive-in racks, pallets are loaded and unloaded from the same working aisle. With drive-thru, pallets are stored from the front aisle and retrieved on the opposite side.
• Mobile racks. Mobile racking systems combine the two advantages of the previous types: they compactly store unit loads while allowing direct access to each pallet. The racks are installed on motorized mobile bases that enable controlled movement of the blocks. These can be joined or separated to open the required aisle as needed.
• Pallet flow racks. In this high-density storage solution, pallets move by gravity along channels equipped with rollers. Loads are inserted in the highest part of the channel and slide forward to the opposite end.
• Push-back racks. This similarly compact storage solution houses several pallets deep and a different SKU per channel. Loads are pushed along slightly sloped channels.

Shelving

Shelving accommodates individual boxes and loose items picked manually. They generally fall into these categories:

• Medium and heavy duty racking. Top-quality shelving supports weights of more than 2,200 lb per level.
• Light duty shelving. This is designed for moderate loads in warehouses, workshops, stores, and offices.
• Carton flow racks. In this gravity flow storage system, goods are placed on slightly inclined roller platforms. This convenience streamlines order picking and ensures SKU turnover.
• Multi-tier shelving. This solution for non-palletized goods consists of combining high-bay shelving with one or more walkways supported by the racking system.

Cantilever racking system and others

Besides picking operations and pallet storage, a racking system can come in handy in several other cases. Cantilever racks, for instance, are specially designed to house long loads (e.g., tubes) and products of varying sizes. It’s also common practice to use specific racks for products such as reels.

Installing racking systems with Interlake Mecalux

Identifying which racking system is ideal for workflows in your center will maximize your throughput. As this decision involves multiple factors, it’s best to count on the guidance of experts.

The result? Floor-to-ceiling storage that can accommodate a far higher volume of products than other solutions. Both drive-in and drive-through are ideal for large inventories with similar SKUs. Both typically boost durability with help from structural steel, which can significantly increase weight capacities while reducing susceptibility to forklift damage.

While these two systems can look virtually identical to the uninitiated, these solutions actually differ dramatically. The main distinctions involve how, exactly, the pallets are placed and picked. 

Drive-in solutions offer cost-effective, high-density storage, in which pallets are simply loaded onto rails situated horizontally. Pallet entry and removal occur in the same location. With a drive-through pallet rack, however, the forklift must load pallets on one side of the rack before eventually unloading them on the other. 

The structural differences between the two solutions means that they are preferred for distinct situations. It's important to understand which types of products and warehouse setups are most conducive to drive-in or drive-through rack structure, then develop the proper systems accordingly. To help, we'll highlight several key differences between the two main types below.

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Drive-In Pallet Racking

As mentioned previously, a drive-in racking system relies on a single point of entry and exit for pallets as they are loaded and unloaded. The name derives from the need for vehicles to only enter on one side. Under this approach, the same SKUs are kept in the same bay.

The drive-in pallet racking system is preferred for last-in, first-out (LIFO) operations, in which the most recently stocked items are also the first to be removed. These solutions provide the greatest storage capacity, thereby maximizing limited warehouse space.

These systems do hold a few downsides, however. The biggest concern is the potential for delays before older inventory is shipped. As such, LIFO is not preferred when expedited shipping is required.

In general, drive-in should be the go-to solution when density is prioritized above selectivity. Yes, there are modest downsides regarding the ability to retrieve items swiftly, but these can easily be offset by the sheer storage capabilities associated with the LIFO solution.

Integration opportunities should also be considered, as drive-in solutions are often paired with push-back pallet racks. Other customization examples include twinlode, dual, or double-wide pallet racking. In select situations, it may be possible to procure customized mezzanines for catwalks, stair towers, or other specialized solutions.

No matter the scope of integration, security and durability are critical, as drive-in systems may otherwise be prone to damage due to increased exposure to forklifts over time.

Drive-Through Pallet Racking

Drive-through racks resemble their drive-in counterparts in several respects but differ in regards to where, exactly, pallets are placed and retrieved. Under this approach, loading always takes place on one side, with unloading delegated to the opposite side.

The drive-through approach enables first-in, first-out (FIFO) storage. Under a FIFO system, products that arrive at the warehouse early on are typically the first to leave. As such, FIFO can easily accommodate many products that aren’t ideal for LIFO storage.

While FIFO is ideal for a greater variety of products, it's often more difficult to implement. It also may be less adaptable than its LIFO counterparts. Its greater selectivity, however, may make it a preferred setup for applications that require higher turnover — especially if modest compromises in terms of storage density are deemed acceptable.

Advantages of These Systems

Drive-in and drive-through pallet racking systems provide a myriad of benefits for many types of industries and facilities. In general, these systems are preferred for high-density operations involving shelf-stable items. This is particularly true of drive-in solutions, which make the most of limited space but tend to be limited in terms of selectivity.

Key opportunities associated with these systems include:

• eCommerce. As compared to other pallet racking systems, drive-in and drive-through solutions provide seemingly endless storage space. Drive-in systems deliver an extra level of cost control, as they can store a higher volume of items within a smaller amount of space, thereby limiting operational expenses. Retrieval processes must be taken into account when choosing a system, however, as selectivity remains a weakness. This may lead to increased shipping times and decreased customer satisfaction.
• Agriculture. Drive-in pallets are often used for consumables, so this solution can be advantageous for certain types of agricultural products. Potatoes, beans, or even seeds are well-suited to this approach, as they can be stored in large quantities for long periods.
• Cold storage. Another often unexpected use of drive-in pallets? Cold or frozen foods. With frozen items, selectivity is typically not as important as density. Drive-in systems are preferable simply because the cost of maintaining freezer space is so high. Given these often exorbitant expenses, it should come as no surprise that enterprises want to make the most of available space. Drive-in LIFO layouts make it possible to accomplish exactly that.
• Beverage storage. Shelf-stable beverages can be stored efficiently and at minimal cost with help from high-density drive-in racking systems. Many companies opt for double-wide drive-in racks for beverage storage, as these easily accommodate transit via refrigerated semi-truck trailers.
• Batch production. When limited SKU counts are required, large batches of products can be stored at reduced cost via a drive-in setup. This is a great option for date-segregated production, particularly when product variation is limited.

When selecting a high-density pallet racking system, think carefully about previously mentioned storage solution downsides, such as limited selectivity and the greater susceptibility to forklift damage.

These concerns can be addressed through proper construction and customized solutions. In many cases, such mitigation strategies will ensure that the benefits of drive-in systems are realized without making unacceptable compromises.

Warehouse1’s Custom Solutions

Whether you prefer drive-in or drive-through pallet racking, you can benefit from the customized warehouse storage solutions that we provide at Warehouse1. We're pleased to offer a variety of high-volume warehouse accommodations that make efficient use of limited space. We know how to make the most of every square foot available.

Ready to optimize your warehouse environment? The experts at Warehouse1 can work with you to develop a strategic system that takes the unique needs of your enterprise into account. When you work with our team, we’ll listen closely to your concerns before helping you craft a solution that is perfectly tailored according to the realities of your industry, your warehouse layout, and your budget. We can also help you prepare for potential pitfalls associated with drive-in and drive-through solutions.

Want more information on drive in racking system? Feel free to contact us.