Warehouses are designed for efficient storage, but the recent surge in eCommerce puts more pressure on warehouses to operate faster and better. Fortunately, there are ways to improve warehouse efficiency, with one of the best tools being racking systems.
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Warehouse racking organizes inventory and maximizes floor space by stacking products vertically. Whether you’re expanding your warehouse, aiming to improve safety, or seeking cost-effective solutions, understanding and leveraging warehouse racking is key to operational success.
By using the right racking system, businesses can optimize space, streamline workflows, and ensure a safe, efficient working environment for employees. This guide will explore the various types of warehouse racking systems, their pros and cons, best practices for installation and optimization, and emerging trends shaping the future of racking.
Warehouse racking is a type of warehouse storage for organizing materials. Racks are metal shelving units bolted to the wall or floor, allowing workers to stack goods vertically. Warehouses may use different types of racking systems to accommodate varying product sizes and weights.
Warehouse racking systems are also known as materials handling systems, or pallet racks. Warehouses use pallets made of wood, metal, or plastic for shelves, and decks are installed in different widths to support goods on the racks.
In many cases, warehouse racking is several feet high and requires forklifts for loading. Warehouse layout plays a major role in warehouse racking because aisle width, docking locations, shipping areas, and other warehouse components affect which options will work in your space.
The goal is to balance efficient storage with ease of inventory accessibility. With proper warehouse racking, managers can maximize space and optimize warehouse organization for efficiency and a streamlined picking process.
Well-designed racks speed up operations and reduce errors. There are so many other benefits to strategic warehouse rack design, including:
Embracing warehouse racks will maximize storage space, but not all businesses follow the same racking system or fulfillment processes. There are several warehouse racking system configurations, each with pros, cons, and unique use cases.
The most commonly used pallet system, selective racks provide access from an aisle. These warehouse racking systems are ideal for narrow aisle racking, standard systems, and deep-reach systems.
However, selective racks require narrow lift trucks and only accommodate a single pallet in depth. Still, they’re ideal for warehouses with a mix of SKUs and high turnover, where employees need selective access to individual pallets.
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Drive-in racks and drive-through racks are ideal for high-density storage and often go from floor to ceiling. Constructed of durable steel, these warehouse racking systems offer enough space for a forklift to move into each bay. It’s important to note that drive-in racks have one entrance and exit, but drive-through racks allow access on both sides of the bay.
As a result, drive-in racks are suited to the last in, first out (LIFO) process commonly used for nonperishable products. On the other hand, a drive-through system requires a first in, first out (FIFO) process.
Cold storage facilities frequently use these racking systems to store perishable goods in high-density storage. However, they’re also popular in industries like manufacturing, where businesses need to store lots of raw materials.
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Typically used for bulk storage, push back racking systems store products that span two to five pallets. When employees load a pallet onto the system, it pushes the next pallet back. When employees unload a pallet, it goes to the front of the rack.
Push-back racking systems utilize the LIFO system, often featuring inclined rails, sliding carts, and double lanes. This warehouse racking strategy is ideal for storing bulk items for retail. It’s also popular in warehouses that need rapid access to products.
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Also known as gravity racks, flow racks are popular for high-density storage. Flow racks use gravity rollers that move with the rack load and feature brakes or speed controllers to regulate item movement.
With this type of warehouse racking system, employees load items at the higher end and remove them at the lower end with a FIFO system. Product rotation happens automatically, as the racks flow with each load. One advantage of flow racks is that they don’t require electricity because gravity powers them.
Flow racks are common in distribution centers, food and beverage industries, and warehouses where strict inventory rotation is critical. They’re ideal for high-volume, fast-moving warehouses with rapid stock turnover.
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Selecting the right warehouse racking system for your facility depends on various factors. The type of warehouse racking that best suits your warehouse varies by need, and there are a few factors to consider that help determine the best option for your company.
High-density racking systems, like flow or drive-in racks, may have a higher upfront cost, but can maximize storage space and potentially reduce costs associated with additional warehouse space. On the other hand, selective racks are less costly to install and reconfigure, but offer lower-density storage.
The amount of floor space in your warehouse plays a significant role in choosing a racking system. High-density racking systems, such as drive-in or push back racks, can store more products in a smaller footprint, making them ideal for warehouses with limited floor space.
Racking systems like selective or flow racks allow storage up to the ceiling, maximizing your available cubic space. When planning, consider your building’s ceiling height, ensuring that your chosen racking system and forklifts can accommodate high stacking.
Some racking systems may require consistent pallet sizes for proper operation, such as flow racks that rely on uniform dimensions to move items smoothly. Make sure your chosen racking system aligns with the type, size, and dimensions of your inventory pallets.
If you manage many SKUs, a selective racking system may be better because of its direct access to each pallet. High-density systems like drive-in racks are more efficient if you have fewer SKUs but higher quantities.
Warehouses with high inventory turnover and frequent pallet access benefit from selective racking, or flow racks, because they support quick retrieval. In contrast, push back and drive-in systems are better for bulk storage with lower turnover and less frequent access.
For perishable goods, racking systems that support FIFO inventory management, such as flow or drive-through racks, are crucial. On the other hand, nonperishable goods benefit from LIFO systems and drive-in racks.
High-density systems such as drive-in or push-back racking are designed for large quantities of pallets with limited access points, while selective racking is better for smaller quantities with a higher focus on accessibility.
Consider the types of forklifts or material handling equipment used in your warehouse and their lifting capabilities. For example, selective racking systems often require narrow-aisle lift trucks to accommodate tight spaces. Drive-in and push-back systems sometimes also require specialized forklifts.
Designing an effective warehouse rack is crucial, but installation is just as important as design. Follow these tips to minimize accidents and ensure safety during warehouse rack installation:
Proper design and installation lay the foundation for successful warehouse racking. However, little optimizations can also go a long way. Follow these best practices to optimize your investment in warehouse racks.
Proper labeling and tagging of inventory stored on warehouse racks can improve organization and inventory management. Barcode labels or RFID tags facilitate easy scanning, enabling accurate stock counts and quick item retrieval. Also, clearly labeled load limits and inventory details prevent employees from overloading the racks.
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Avoid damaged or faded rack labels. Go with Camcode’s durable labels and tags, which are rated to last up to 20 years in even the most rugged environments.
The best inspection routine depends on the complexity of the racking system, load weights, and frequency of use. Racks with more complex setups and components will need more regular inspections.
Conduct regular inspections to detect any signs of wear, damage, bending, or loose bolts. Ensure all anchor bolts are secure and the beams are locked in place.
Consider your environment, too. If you’re in a humid environment, for example, inspect for rust or corrosion and treat affected areas promptly to maintain the rack’s structural integrity.
Maintenance is also crucial. Create a maintenance schedule that includes periodic tightening of bolts, replacing worn-out components, and repairing damaged sections.
For racks with moving components, such as push back or flow racks, ensure that rollers, tracks, and other moving elements are regularly lubricated and free of debris.
Train employees on proper loading and unloading techniques, emphasizing safe handling practices and how to prevent overloading. For example, ensure your team evenly distributes loads across beams to avoid tipping, leaning, or collapse.
Train them to always place heavier loads on lower shelves to reduce stress on the system.
It’s also crucial to ensure specialized employees have relevant training and certifications. Forklift operators must be up-to-date with their certifications. Aside from tracking certifications, ensure forklift operators understand how to safely navigate around racks and avoid collisions.
Warehousing space — and, by extension, racking — is increasing in demand. With the surging demand for eCommerce, businesses need more warehousing space.
It’s therefore no surprise that the global warehouse racking industry is projected to grow tremendously, with experts predicting it will reach over $14 billion by (a CAGR of 4.12%).
However, racking won’t stay stagnant, and warehouse racking is experiencing a surge of innovation that promises to improve efficiency and safety.
Consider the following warehouse racking technology trends:
Warehouses are already relying on automated systems and robots to make racking faster, efficient, and safer. AS/RS technology automates the storage and retrieval of goods, reducing the need for manual labor. It also speeds up picking speed and accuracy.
Warehouses are increasingly integrating autonomous mobile robots (AMRs) and automated guided vehicles (AGVs) with racking systems to retrieve items more efficiently.
These technologies will likely become more ubiquitous as demand for warehouses grows and costs for these technologies go down. Experts also predict they will have an impact on the market for pallet racking, which will grow at an impressive CAGR of 9.31% by .
It’s easy to adjust modular racks to meet changing inventory demands. More warehouses are embracing this approach to be as flexible as possible in light of fluctuating demand, storage needs, seasonality, and space constraints. Some modular solutions are more expensive upfront, but the long-term benefits easily outweigh the initial investment.
There is a growing trend toward using recycled and eco-friendly materials in racking components to reduce environmental impact. By maximizing vertical and horizontal space, modern racking systems also lessen the need for additional real estate.
With rising real estate prices, more warehouses are opting for high-density racks out of necessity. This approach maximizes existing footprints, which cuts costs and carbon emissions, helping businesses be more sustainable and profitable in the long run.
Warehouse racking is a straightforward but crucial tool for ensuring efficiency and safety, and choosing the right racking system for your inventory and business supports long-term growth and success.
Follow the best practices in this guide to select the best warehouse racking system, optimize it for efficiency, and plan for the future. Investing in modern racking solutions is not just about storage — it’s about creating a smarter, safer, and more sustainable future for warehousing.
Maximize your warehouse efficiency and safety with Camcode’s durable warehouse racking labels and tags. Designed to withstand harsh conditions, our high-visibility labels make inventory tracking and management seamless. Request your free label sample kit to find the perfect labeling solution for your racking system.
19 July
In today’s fast-paced business landscape, companies face the critical challenge of optimizing their storage and logistics operations. The right storage racking solution is the backbone of any successful warehouse. It can make a substantial difference in efficiency, productivity, and overall profits.
By investing in an effective racking solution tailored to their specific needs, companies can unlock a myriad of benefits. These include optimal space usage and improved organization, to enhanced inventory management and streamlined workflows.
In this article, we will delve into the compelling reasons why companies should consider warehouse racking as a strategic investment.
The right storage racking solution can significantly impact the efficiency and productivity of a warehouse. Discover some of the reasons why a company with a warehouse production should invest in a suitable storage racking solution:
Warehouse racking systems allow companies to maximize the use of available space. These solutions utilize vertical space in order to use every possible storage space effectively. This provides a greater storage capacity without expanding the physical footprint of the warehouse. This solution can help companies make the most of their available space and avoid the need for costly facility expansions.
For example, if your company uses a lot of pallets, implementing a pallet racking system could be beneficial. This type of storage can increase pallet flow and guarantee easy access to them. With everything stored neatly and out of the way, this racking system can significantly facilitate materials handling.
A well-designed racking system provides proper organization of products. It makes it easier to locate and retrieve items when needed. It ensures the systematic and logical storage of goods, reducing the time spent searching for specific items. This leads to improved efficiency in order picking and fulfillment processes.
Warehouse racking systems provide efficient order picking, increased storage density and optimal inventory control.
Improve both inventory control and management by implementing labeling and tracking systems within the racking structure. This way, companies can accurately monitor stock levels, track product movement, and implement effective inventory rotation methods.
Notably, stock-outs, inventory redundancy, and product obsolescence are all risks that an effective racking solution can reduce or eliminate.
Investing in high quality and reliable racking systems promotes a safer working environment. Properly designed and installed racks reduce the risk of accidents, such as product falls or collapsing racks. Accidents which can cause damage to goods and potential harm to employees. It is crucial to consider safety features like load capacity, appropriate anchoring, and compliance with relevant industry standards to mitigate risks.
Additionally, manufacturers design several warehouses racking systems to store materials in a safe and ergonomic manner. Carton flows and roll out pallets are both examples of types of racks to offer that. Employees can access items without the need for excessive reaching, bending, or stretching. This reduces the risk of injuries associated with poor ergonomics.
Customizing storage racking solutions to meet specific warehouse requirements is possible. Moreover, most warehouse racks designs are flexible and adaptable. This enables easy adjustments to accommodate varying inventory sizes, seasonal fluctuations, or evolving business models. This ability to evolve helps companies optimize their storage infrastructure and adapt to future growth.
An efficient racking system streamlines warehouse operations, reducing the time and effort required to handle goods. With improved organization and accessibility, employees can quickly locate and retrieve items, leading to faster order fulfillment. This results in increased throughput, reduced labor costs, and improved customer satisfaction due to shorter lead times.
The right storage racking solution optimizes workflow within the warehouse. By reducing the need for excessive movement, it minimizes time wasted in navigating through the facility. This enables employees to focus on value-added tasks, such as order fulfillment, rather than searching for or rearranging inventory. A well-organized and efficient warehouse environment boosts overall productivity.
This improves overall productivity and minimizes labor costs. It also increased the number of orders processed within a given time frame.
For businesses with warehouse production, racking systems pave the way for enhanced operation excellence and competitive edge in their industry. At Roll Out Racks, we offer high quality warehouses racking solutions, such as roll out pallets, built with thick structural steel. Equip your warehouse with our racking solutions and take your operation to the next level.