Pallet Rack Wire Decking

Pallet Rack Wire Decking

As a warehouse manager or owner, two of your topmost priorities are efficiency and safety. A good racking system can help you improve both, while pallet rack wire decking can add an even further boost to the speed and security of operations.

Wire decking is essentially a mesh of extremely strong and durable wires that you can fit inside each bay of your storage racking system to offer additional support for pallets or individual boxes and products. Although pallet rack decks are optional, they pay off in the long run because they help your employees stay safe and help keep your inventory intact.

Wire vs Solid Pallet Rack Decks

Wire vs Solid Pallet Rack Decks

There are several types of pallet rack decking you can use to enhance the safety and efficiency of your warehouse storage system. To keep it simple, they can be split into two main categories, solid decking and wire decking.

In both cases, the aim is to provide additional support for your pallets as compared to the use of crossbars alone. When you employ at least two crossbars for each pallet slot, you reduce “beam spread” and the possibility that a broken pallet will fall through different beam levels and damage your products. In addition to this, pallet rack decks provide a horizontal platform to better hold up pallets and individual boxes or products. The obvious advantage is that you can safely store inventory that is not necessarily palletized.

There are significant differences between solid and wire pallet rack decks. Solid decking, for instance, commonly consists of wood or metal platforms, is heavier and more difficult to install, and can also be more expensive. In what follows, we focus on wire decking, its characteristics, advantages, and potential drawbacks.

Basic Characteristics of Wire Decking

01

Unlike solid decking, pallet rack wire decking is made up of crossed vertical and horizontal strands that allow spacing at various intervals. Although wire decking might seem to offer less support, with the addition of U channels under the wire deck panel, it is suitable for weights upwards of 3,800lb or 1,700kg.

02

Due to its configuration, such decking better distributes weight across its entire surface. It also ensures that the weight of inventory is evenly distributed across the surface of a pallet, as opposed to the beams alone. Long-term, this helps extend the lifespan of pallets and avoid losses from broken pallets and goods.

03

The fact that employees can see through the wire mesh is another notable characteristic of wire decking, especially when compared to its solid counterparts. Although this might not seem like a big deal, visibility plays an important part in avoiding accidents, as well as in how quickly pallets are loaded and unloaded.

04

Finally, you’ll notice that wire decking for pallet racks is easily installed and requires no additional hardware. It is simply fit into place, but for this to work, you must work with the exact specifics of your racking system. There are different types of pallet rack wire decking and each can be further customized for specific requirements.

Pallet Rack Wire Decking: Uses and Advantages

Any type of pallet rack decking is better than no decking at all, but wire pallet racks present numerous advantages when compared to their solid counterparts. These include:

Easier compliance with strict fire codes.

Wood decking is not the ideal material to work with in case of a fire, while metal decking is highly incompatible with above head emergency fire sprinklers. Wire decking for pallet racks presents none of these inconveniences, which is also why it is actually required by fire codes in some regions. Such decks are never built from flammable materials like wood and, because they are essentially a mesh of wires, they allow smoke to rise and water to easily pass through them for better management of emergency situations.

Wire decking is overall safer for stock and employees alike

In the absence of any kind of pallet rack deck, pallets must be placed directly onto support beams. The margin of error for employees operating forklifts to this end is extremely small, which makes it likely that they will misplace pallets and eventually cause them to fall and break. Wire decking helps prevent these accidents, as well as more severe cases where the employee is also in danger of injury.

Pallet rack wire decking enhances visibility

The mesh allows more light to pass through than a solid deck, which helps employees read labels correctly and avoid mistakes. It also allows forklift operators to identify the margins of pallets with increased accuracy, which makes the loading and unloading process quicker and safer.

More durable and lighter than other materials

When compared to wood pallet rack decking, for instance, wire decking can support more weight and is less likely to suffer from mildew and mold. Long-term, the latter type of support is also less likely to bend, warp, sag, or break, which translates directly into better return on investment for your warehouse.

The cost of wire decking is lower than that of solid steel shelf decking, which can help reduce the required initial investment.

Are There Any Drawbacks to Wire Decking
Are There Any Drawbacks to Wire Decking?

There are no obvious disadvantages to using wire decking as opposed to other pallet rack decks. If you compare the former with a solid metal deck, for instance, you might be tempted to think that it cannot withstand the same weights. This, however, is not the case.

Of course, wire decking does come in several types and some are more suitable than others for heavy-duty loads. A standard wire deck, for example, is commonly built to support between 2,000lb and 2,500lb, while a light-duty deck will naturally handle lighter stock. Meanwhile, heavy-duty wire decking can withstand up to 3,800lb and more. This is easily comparable to the weight capacity of any solid pallet rack deck.

Wire Decking for Pallet Racks: Different Types

In addition to different weight capacity features, wire decks can be classified according to the way they fit in with the rest of your storage system. Some of the most common types include:

Wire Decks
Wire Decks

Standard wire decks, with welded support channels placed on beam steps and a waterfall margin design that fits over each beam.

Flared channel
Flared channel

Flared (and inverted flared) channel, with a flared flange at both ends of the deck that ensures a fit with both box and step beams.

Inverted channel
Inverted channel

Inverted channel, where support channels are positioned upside down in order to avoid the accumulation of debris.

Text Block
text block

Flush (or drop-in) wire decks, with an inside waterfall or with the end wires bent towards the inside edge of the beam.

The type of wire decking you choose has to do with the specific dimensions and characteristics of your storage system. Remember that the decks are not installed using additional hardware, which means they must fit in perfectly with your storage racks.

How to Choose the Right Pallet Rack Deck for Your Warehouse

Unlike other pallet rack decks, wire pallet racks are highly customizable. To make an optimal choice for your warehouse storage system, consider the following questions.

What Kind of Stock Do You Handle?

Not all wire decks are made equal. Some are better able than others to handle large and heavy loads, which is why it’s essential that you take into account the type of stock you commonly handle in your warehouse. Implementing light-duty decks for heavy inventory can lead to costly accidents, whereas the reverse can be a waste of financial resources.

How Will You Store Stock?

Do you store your inventory in full pallets, in individual boxes, or both? The answer can determine which type of wire decking you should implement in terms of mesh density. If you store most goods in pallets, for instance, then a wide mesh is sufficient to ensure the necessary support. If, on the other hand, you also store products individually or in boxes, then a tighter mesh pattern can prevent the latter from falling between beams.

What Kind of Warehouse Environment Do You Work With?

For example, do you handle goods that require low temperature conditions or do you store products outdoors? For the majority of applications, enamel finish (either power coated on baked on) is suitable, but if moisture or oxidation are a concern, then galvanized or stainless steel is more appropriate. The same question can help you determine the type and positioning of support channels for your wire decks. Especially if you operate in the food and beverages industry, your storage system can benefit from inverted channels for wire decking because the latter decrease the accumulation of dirt, dust, and debris, and are easier to clean.

Pallet Rack Wire Decking from Kingmorack

At Kingmorack, we accessorize innovative storage solutions with customizable wire decking for pallet racks in order to ensure the longevity of each system. While wire decking is, of course, an optional feature, we recommend it to all warehouse managers and owners who wish to increase both the efficiency and the safety of their operations.

We also understand that pallet rack wire decking must fit a system perfectly in order to function optimally. For this reason, we put our knowledge and experience at your disposal and help you come up with the best solution for the specific requirements of your warehouse. For more information, contact Kingmorack today.

Discuss your order

For more information, quotes, sample and orders, contact Kingmorack today.

Double Deep Pallet Racking

Double Deep Pallet Racking

Double deep pallet racking functions similarly to selective racking, but allows the use of two bays in the deep direction, with one placed behind the other. This type of storage system can save anywhere from 15% to 30% more space than fully selective racking because it can remove 2 out of 5 aisles as compared to 100% selective pallet racking. It is more affordable to implement than a two pallet-deep push back system, but it requires a double deep reach forklift to load and unload pallets.

It’s also fairly easy to convert selective racking into a double deep system and vice-versa with minimal costs, whereas the main disadvantage with the latter is some loss in accessibility. Below, you’ll find more details about double deep pallet racking systems and whether they are a suitable storage solution for your warehouse.

Basic Characteristics of Double Deep Pallet Racking

Basic Characteristics of Double Deep Pallet Racking

A double deep racking system consists of upright frames and beams that allow the storage of two pallets in the deep direction for additional space-efficiency. While using this type of storage, you can ensure direct access to a maximum of 50% of pallets, with the remaining 50% deposited to the back. As such, unlike selective racking, the system no longer allows FIFO (First-In-First-Out) management of inventory. Employees can access stock on a FILO (First-In-Last-Out) basis, which can be unsuitable in some industries.

Another thing to consider when implementing double deep pallet racking is that specialized vehicles are needed to access both pallets on each row. These vehicles include reach trucks, articulated forklifts, and even regular forklifts equipped with double deep hydraulic attachments. While the former can double your initial cost, the latter is an affordable solution that requires minimal additional investment.

Depending on which handling vehicle you use, aisles in a double deep pallet racking system will take up different amounts of space. For counter-balanced reach trucks, you’ll likely need 3.8m to 5.5m of clear space per aisle, while an articulated forklift will require as little as 1.8m to 2.2m. Regardless of this choice, you’ll save aisle space when switching from a selective system to double deep racking because the latter will allow you to deposit four back to back pallets instead of just two and, as such, fewer aisles will be necessary overall.

Double Deep Racking: Uses and Advantages

There are a number of significant advantages that recommend double deep racking systems over selective and push back ones. These include:

Additional storage capacity.

Double deep pallet racking is particularly useful when you increase your stock or introduce a new line of products. It allows the storage of more pallets per SKU, as well as an effective way to organize inventory.

Increased floor space utilization

Once a warehouse is converted to a double deep pallet racking system, unnecessary aisles can be removed and additional floor space can be freed up for more effective operations. Given the right layout, floor space utilization can be increased by as much as 55%.

Direct access to 50% of pallets

Although double deep racking is not a fully selective storage method, it is nevertheless more selective than a push back alternative with three to six pallets-deep bays. Half of all products can be accessed directly and what is lost in accessibility compared to a selective system can be made up in effective management. For instance, a single SKU can be assigned to each bay so that operators are not often required to access the back pallets.

Less expensive than push back racking

Double deep racking systems are similar to push back storage solutions that go two pallets-deep, but they are much cheaper to implement. If budgeting is an issue, this can be a lifesaving alternative.

Flexibility

Selective racks can easily be converted into double deep pallet racking systems and vice-versa with minimal costs. This is especially useful in warehouses that handle varying stock volumes over different periods of time.

Double Deep Racking Systems: Drawbacks

Like most storage solutions, double deep pallet racking is not suitable for all applications. Some of the significant drawbacks to consider include:

Reduced accessibility compared to a selective system

While a selective system permits direct access to 100% of products, this is not the case with double deep racking, which can be a problem for warehouses that store a small number of pallets per SKU

FILO access.

Some sectors work with products that have a very limited shelf life. In these cases, FIFO inventory management is preferable and, at times, absolutely necessary, which makes the implementation of double deep racking systems unfeasible.

Special vehicles or accessories are needed.

Double deep pallet racking will incur additional implementation costs if specialized vehicles are not already available. Accessories for existing forklifts or reach trucks can be used as more affordable alternatives.

Double Deep Pallet Racking from Kingmorack

Overall, a double deep racking system is most suitable for warehouses that are pressed for space, but that do not handle a large number of pallets per SKU and that do not deposit perishable goods. Still not sure whether this type of storage is the optimal solution for you?

At Kingmorack, we design, build, and deliver all kinds of storage systems for diverse space and inventory requirements. Contact us today to discuss the specific details of your project and whether double deep racking is the best fit for you.

Discuss your order

For more information, quotes, sample and orders, contact Kingmorack today.

Narrow Aisle Pallet Racking

Narrow Aisle Pallet Racking

Narrow aisle pallet racking is the most space-efficient form of selective storage you can implement in a warehouse. It offers the benefit of unrestricted access to each deposited pallet while reducing the amount of space wasted on aisles.

By switching to a narrow aisle rack system, you can save up to 45% more space than with conventional racks, but this is not necessarily feasible for all applications. In addition, narrow aisle racking requires the use of a specialized narrow aisle forklift (also called a turret truck), the cost of which must be added to the initial investment.

Below, we detail the characteristics, advantages, and optimal uses for this type of storage rack system to help you determine whether it is suitable for your warehouse space.

Basic Characteristics of Narrow Aisle Pallet Racking

Basic Characteristics of Narrow Aisle Pallet Racking

Narrow aisle pallet racking is a selective storage system, which means that each deposited pallet can be accessed directly by means of a turret truck. The system functions on both a FIFO and FILO (First-In-First-Out/ First-In-Last-Out) basis and is therefore suitable for inventory that must be rotated regularly. Differently put, this type of storage can support items with a limited shelf life because the goods that are first deposited are also the first to be removed. At the same time, it works for items that require FILO inventory management because the system offers 100% selective access to each pallet.

If a typical selective racking system requires anywhere from 3m to 4.5m of clear space per aisle, narrow racks can reduce this number to only 1.8m (or just under 6ft). The amount of space you can save is, as such, significant, but the trade-off is that you need specialized vehicles in order to load and unload products.

A turret truck, also known as a VNA (very narrow aisle) truck is designed with the sole purpose of operating in tight warehouse aisles. Using a turret truck, storage becomes a “man up process” in the sense that the operator is lifted with the forks to a height of up to 14m (or approximately 45ft). This ensures not only accessibility in tight spaces, but also enhanced visibility for the operator and an overall quicker order picking process.

Narrow Aisle Racking: Uses and Advantages

Narrow aisle pallet racking offers a number of considerable benefits when compared to other warehouse storage solutions. These include:

Optimal use of available space.

When you are pressed for space, investing in narrow racks can be significantly less expensive than acquiring an additional warehouse or extending an existing one. Narrow aisle racking essentially pushes racks closer together for maximal space efficiency and can go as high as 14m (or 45ft), provided that your warehouse roof allows it.

Unrestricted access to individual pallets

Narrow aisle pallet racking emulates the features of selective racking, which is to say that a turret truck operator can easily access any pallet at any given time, on a FIFO basis. Unlike selective systems, however, narrow racks make better use of available space and allow you to store an even wider variety of SKUs (stock keeping units).

Faster order picking

Especially when coupled with turret trucks, narrow aisle racking ensures that employees can carry out order picking from pallets much faster than with other storage systems. Turret trucks can be used to load and unload pallets, but also to lift operators to any bay so that they may select and remove products directly.

Overall, narrow aisle pallet racking is suitable for all warehouses that prefer a selective system with FIFO access, but are struggling with available space. Warehouses with a wide variety of products (or a low number of pallets per SKU) that prioritize high selectivity and precise retrieval of products rather than entire pallets have most to gain from this type of storage.

Narrow Aisle Racking: Drawbacks

Like with most racking systems, the advantages of narrow aisle pallet racking can quickly turn into drawbacks if implemented in an unsuitable environment. Disadvantages associated with this type of storage include:

Aisles that are too narrow can decrease efficiency

Some warehouse managers attempt to save every possible bit of space by reducing aisles to unreasonable dimensions. When turret trucks barely fit inside an aisle, operators have considerably less room for error and are therefore more prone to costly mistakes. As such, floor guide rails are a must to prevent the truck from hitting the racking system.

Single aisle access.

Because the spaces between racks are so narrow, no more than one turret truck can operate in a given aisle at a time. If your warehouse sees a lot of fast-paced activity that requires the concomitant use of several forklifts per aisle, then it’s likely you will lose in efficiency what you gain in additional space when you introduce narrow racks.

Relatively high initial costs.

Narrow aisle racking is not necessarily more expensive than selective racking, for instance, but it does come with the added cost of specialized access vehicles such as turret trucks.

Narrow Aisle Pallet Racking from Kingmorack

At Kingmorack, we boast years of experience with all types of warehouse storage systems. As such, we are best equipped to assist you as you design and plan the optimal narrow aisle racking solution for your space.

To discuss the specifics of your project and whether narrow racking is the best option for your storage needs, contact Kingmorack today.

Discuss your order

For more information, quotes, sample and orders, contact Kingmorack today.

Selective Pallet Racking

Selective Pallet Racking

Selective pallet racking is a type of storage system where each individual pallet can be reached directly. The system is one of the most affordable to implement, but also has the lowest storage capacity compared to other options. For some warehouses, such as those where food, beverages, and other perishable goods are stored, it is one of the few storage solutions that offer suitable access for day-to-day activities.

In what follows, we’ve included details about the exact layout and characteristics of a selective pallet racking system, as well as its advantages and drawbacks. The information is meant to give you a better idea of whether this type of storage is adequate for your warehouse management and business.

Basic Characteristics of a Selective Pallet Racking System
Basic Characteristics of a Selective Pallet Racking System

In a selective rack system, goods are deposited only one pallet deep. At most, two pallets can be placed back to back in two separate, adjacent racks for an effective use of space and minimal aisle requirements. Selective racks are not limited in terms of height, however. On average, they are between 10 and 15 feet tall, but they can go up to 35 feet or more if you have adequate equipment to remove and store goods at such heights.

There are several consequences to the way selective racking works, but one of the most important is that this type of storage allows FIFO, or First-In-First-Out, access. Compared to a FILO (First-In-Last-Out) system, selective racking means that the stock you’ve deposited first can also be removed first. If your warehouse primarily stores products with a short shelf life, then FIFO access is likely a must.

Aisle space is another matter to consider when you decide between different storage systems. For selective rack systems, you’ll need more aisles because the racks go only one pallet deep and, as such, your lanes can be only two pallets wide for back to back bay, at most. If your warehouses uses reach trucks, aisles for selective racks should range from 10ft to 11.5ft each, whereas for counterbalanced forklifts, you’re looking at clear aisles of 11.5ft to 15ft.

Selective Rack Systems: Uses and Advantages

Selective pallet racking systems present multiple advantages that can be leveraged to improve the efficiency of your warehouse:

Direct access to each pallet

When you use selective racks, no pallet is out of the reach of a forklift. This is particularly useful when you store a wide variety of products or when employees are frequently required to perform order picking from pallets.

FIFO access

When you deposit food and other items with a very limited shelf life, your inventory must rotate constantly. Otherwise, you run the risk that goods first deposited become spoiled and unusable. To maintain a good rotation, FIFO access is ideal.

Multiple access per aisle

In any selective storage system, more reach trucks or forklifts can operate in the same aisle at the same time. This can have a significant impact on the efficiency with which orders are delivered and goods are stored.

Cost-effective

Selective pallet racking systems are the most affordable form of warehouse storage per square foot. In addition, you don’t need special forklifts to access selective racks, which brings down the total cost even further

The type of warehouse that is best served by a selective rack system stores a wide range of products or, in other words, a small number of pallets per SKU (Stock Keeping Unit). Selective racks are ideal for warehouses that see a lot of traffic and where pallets are frequently taken down for order picking before being stored again. Industries dealing in perishable goods are good candidates for this type of storage systems and so are e-commerce businesses, where efficient order-picking is crucial for the well-functioning of the entire enterprise.

Selective Pallet Racking: Drawbacks

A selective pallet racking system is not suitable for all applications. Some of the drawbacks to consider before implementing this type of storage in your warehouse include:

Large space requirements

Because more aisles are needed to efficiently operate a selective rack system, you’ll need more space overall to store the same amount of stock. This is not necessarily a problem for some warehouses, but if you handle more than 3,000 pallets at a time, selective racks might not be the most space-effective means of storage for you. The same can be said if you store a large number of pallets per SKU, which means that you can make better use of systems going several pallets deep.

Higher costs for above medium volume stock.

A direct consequence of considerable space requirements is that if your warehouse handles stock in medium to high volumes, you’ll end up paying for more space and additional units to store everything in selective racking. Push back or similar solutions, on the other hand, will reduce your expenses in these instances.

Selective Pallet Racking from Kingmorack

Kingmorack manufactures and delivers durable selective pallet racking systems to warehouses, businesses, and homes worldwide. We understand the ins and outs of each type of storage we sell and, as such, we are able to advise you further regarding the most suitable fit for your space.

To get more information on selective racks or on any other storage solution, contact Kingmorack with the details for your project.

Discuss your order

For more information, quotes, sample and orders, contact Kingmorack today.

Structural Pallet Racking

Structural Pallet Racking

Structural pallet racks are the most solid, heavy-duty solution for warehouse storage currently on the market. They are suitable for several applications outside the warehouse, but they are particularly useful in deposits that see dense forklift traffic.

Structural racking is mainly distinguished from roll-formed pallet racks, which follow an alternative design, through characteristics such as load capacity, stability, and durability. Below, we explain the difference in detail with particular focus on the ideal uses of structural racks.

Structural Pallet Racks vs. Roll-Formed Pallet Racks

Structural Pallet Racks vs. Roll-Formed Pallet Racks

Pallet rack systems can be classified according to several features, but some of the most popular options include:

The differences between structural and roll-formed pallet racks come primarily from the way these two racking posts are constructed. On the one hand, roll-formed racks are built from multiple sheets of steel that are bent together several times until they acquire the desired upright shape. Depending on how many sheets of lengthwise steel are used in this process, a roll-formed rack can be more flexible or more rigid, with direct consequences on its ease-of-use, strength, and load capacity.

Structural racks, on the other hand, are made by melting steel and casting it into a mold with an upright form of various lengths. Some of the most common forms are I-Beams and C-Channels, which present various advantages from load support to hygiene. Once the frames are cooled, structural racks become their strongest and attempts to bend or modify them further are ill-advised. Overall, they are much stronger and sturdier than roll-formed pallet racks, often at the cost of reduced flexibility and higher prices.

The way horizontal support beams are connected to these two types of uprights is also different, which leads to additional distinctions between the latter. Rivet-style connectors are commonly used in roll-formed pallet racks, which further extends their flexibility, while structural racking is often held in place with bolts, which adds even more strength to an already capable system.

Structural Racks: Uses and Advantages
There are several reasons why one might prefer structural racking over its roll-formed counterpart. These include:
Greater strength

Structural racks are more suitable to support bulky, oversized, or ultra-heavy loads because of the way they are built. This is not to say that roll-formed racks are not strong enough for most warehouse applications, but only structural racks are designed to withstand heavy-duty inventory.

Rigidity and stability

A structural racking system is sturdier and more rigid than a roll-formed rack, not only because of its manufacture, but also because it is held together with bolts, rather than rivets. For this reason, structural pallet racks are a popular choice for heavy load industry applications and especially in regions with high seismic activity.

Lifespan and durability

Structural pallet racks are better equipped to withstand impact from forklifts and other warehouse vehicles, especially when they are installed with additional protectors. Long-term, this can significantly extend the lifespan of a racking system and contribute to a higher return on investment.

Hygiene

Structural racking is commonly built with an open, C-Channel construction, which means the entire system is easier to wash down and sterilize. For some industries, such as food and beverage distribution, this can be a significant advantage

Versatility

Unlike their roll-formed counterparts, structural racks can be customized for numerous space requirements and applications. For instance, they are used in most selective, push back, drive in, and pallet flow storage systems. Due to their galvanized finish, they can also be used outdoors

Warehouses with a fast-paced schedule, including cold storage deposits, food and beverage distributors, or other high volume storage facilities with constant forklift traffic, benefit most from the implementation of structural pallet racks. Overall, the latter can withstand heavier loads per surface unit and are more likely to survive long-term if damaged by vehicles or employees.

Structural Racks: Drawbacks

The rigidity of a structural rack can be a benefit as much as it can be a disadvantage, depending on the particular application you have in mind. Other drawbacks to consider before implementing such a system include:

Versatility

A structural pallet rack is installed using nuts and bolts, usually by a professional. The entire process can take longer than in the case of roll-formed racking, which requires no additional hardware.

Less flexibility

Once a structural racking system is put into place, it can be difficult and time-consuming to adjust its position or beams for different load sizes and weights. Roll-formed racks are much more adaptable in this respect because their boltless connections can be easily undone and repositioned.

Higher costs

The manufacturing process for structural racking is more expensive and so is the final product. A structural racking system is often heavier than a roll-formed alternative, which means transportation might also cost slightly more.

Structural Pallet Racking from Kingmorack

To make the most out of your new pallet racking system, you must balance the advantages and drawbacks of each option against the specific requirements of your space and business. At Kingmorack, we put our experience at your disposal for optimal decisions in terms of storage space.

To find out more about whether structural pallet racking is the right fit for your warehouse, contact Kingmorack today and give us the specifics.

Discuss your order

For more information, quotes, sample and orders, contact Kingmorack today.

Push Back Pallet Racking

Push Back Pallet Racking

Push back pallet racking is one of the most space-efficient forms of storage racking used primarily in warehouses and other large facilities. Unlike selective racking, pushback pallet racks go several pallets deep in order to maximize the use of space and reduce the extent of aisles

Push back racking is not necessarily the optimal storage solution for all applications, however. In what follows, we introduce the basic characteristics and mechanisms of pushback racks to help you decide whether their implementation is worthwhile for your project or whether a different storage approach is more advantageous.

Basic Characteristics of Pushback Pallet Racks

Basic Characteristics of Pushback Pallet Racks

The primary difference between selective racking and push back racking is that the latter permits the storage of two to six back-to-back pallets in the same bay. To make this possible, a push back rack system usually features inclined rails on either sides of a bay and several nesting carts designed to move back and forth on these rails.

To load a lane (or bay), an operator uses a reach truck or forklift to first place one pallet on the top nesting cart. To deposit the next pallet, the operator correctly positions it in the following cart and then pushes it against the previous pallet. The process continues in the same manner until the last pallet is loaded directly on the rails and all the other units have been pushed back as far as possible.

The system functions in basis of FILO (First-In-Last-Out) access, which means that the stock deposited first is pushed to the back of the lane and can only be removed last, after the previous units are unloaded. Overall, what pushback pallet racks save in used space by compacting pallets together, they lose in accessibility, because not all stored pallets can be accessed directly. This is why, like all storage systems, they are only suitable for certain applications.

Pushback Racking: Uses and Advantages

When you implement push back racking in your warehouse, these are some of the advantages you can expect to gain from the investment:
Maximal use of available storage space

Not only do push back rack systems allow you to build vertically in your warehouse, but they also reduce the amount of space between pallets and the space you use for aisles as compared to other storage solutions. To correctly implement pushback racks, you’ll likely need aisles of 10ft to 11.5ft each, but not as many aisles will be required as compared to a selective racking system, for instance.

Space- and cost-efficient for medium to high volume stock

Selective racking does come with its own advantages, but for warehouses that store upwards of 3,000 pallets, they become too costly in terms of used space and expenses. Pushback pallet racks are an elegant solution to this issue. If you are pressed for space and if you deposit a large number of pallets per SKU (stock keeping unit), this type of storage is ideal.

Quick loading and unloading

With pushback pallet racks, the operator is not required to enter the rack itself, which makes for a faster storage and order picking process. Increased safety is also a noteworthy consequence of this advantage, as well as an extended lifespan for the equipment itself.

Enhanced organization and order picking

Pushback racking can often be complemented with the use of color-coded carts and an innovated inventory system to significantly improve efficiency in a warehouse. Because you can store the same type of products in separate lanes according to criteria that work for your business, your employees will find it easier to identify and remove the right pallets when preparing an order.

All in all, pushback racks are most suitable for warehouses that store medium to high volume stock, as well as upwards of five pallets per SKU. A good push back rack system can save up to 65% more space than selective racking and will, as such, ensure that you make the most of the space available in your warehouse.

Pushback Racks: Drawbacks

Due to the nature of pushback racks, their use is not recommended in certain warehouse applications. The drawbacks to be considered include:

Not all pallets are easily accessible

This is not a problem if your warehouse delivers orders comprised of entire pallets, but it can become an issue if your employees have to do order picking from pallets. If this is the case, then the cost and space you save by investing in pushback racking, you will likely lose in employee and order picking efficiency.

FILO access is not suitable for all applications.

For instance, the food and beverage industries work with perishable goods that must be constantly rotated before they become spoiled. A FIFO type of system is better equipped for this task.

A wide variety of products can be a problem.

When you use pushback racking, you want each lane (or bay) to consist of similar or identical products, but this won’t be possible if you store small numbers of pallets per SKU. For the latter case, a selective racking system is more advantageous.

Pushback Pallet Racks from Kingmorack

Our pushback pallet racks come with a number of features and customizable options that ensure a perfect fit for your warehouse storage.

If you’re not yet sure that pushback racks are the right option for you, contact us at Kingmorack with the specifics of your project. We put our vast experience in storage solutions and a wide range of products at your disposal.

Discuss your order

For more information, quotes, sample and orders, contact Kingmorack today.

Mobile Racking Systems

Mobile Racking Systems

Mobile racking systems are a form of high-density storage for warehouses and deposits handling high volumes of stock, inventory that requires special ambient temperatures in order to remain intact, or both. In terms of storage capacity, this type of racking system is similar to push-back or drive-in racks. Unlike the latter two, however, moveable racking systems offer 100% selectivity.

As such, mobile racking is a suitable storage solution for inventory that requires both FIFO (First-In-First-Out) and FILO (First-In-Last-Out) management. In addition, it can drastically increase storage capacity in a warehouse without sacrificing accessibility.

Of course, like most types of storage, mobile racking systems are not necessarily suitable or cost-effective for all applications. In what follows, you’ll find additional details that can help you decide whether this is the right storage solution for you.

Basic Characteristics of Mobile Racking

Basic Characteristics of Mobile Racking

In a mobile rack storage system, several racks are placed on wheels and rails, as well as grouped together in a block. For maximum storage capacity, each block includes enough free space to fit only one aisle, while the racks are packed together without spacing. In order to access a pallet on a specific rack, the operator must first move the racks in such a way so as to create an aisle at the right location. They can then enter the aisle, deposit or retrieve a pallet, and return the rack to its initial location.

All mobile racking systems are placed on a moveable base and guided rails. Depending on how they are moved, however, such systems can be classified as follows:

Manually operated. In a manually operated mobile system, the operator must move the racks with the help of handles in order to create enough aisle space for a forklift.

Mechanically assisted. Mechanically assisted systems employ multi-ratio geared hand wheels that are mounted on shelves. The latter help operators create the necessary aisle space, as well as load and unload heavy items.

Electrically powered. With electrically powered mobile racking systems, the racks are operated with the help of an integrated control panel and inventory software. Employees can move racks simply by pushing a button, which can greatly reduce handling time and increase warehouse efficiency.

Optimizing Warehouse Logistics

Mobile racking is much more advantageous than its conventional, selective counterpart when it comes to storage capacity and the efficient use of warehouse space. By implementing movable racking systems in your warehouse, you can store up to 100% more pallets in any given area and gain up to 44% more floor space.

Yet the most significant characteristic of this type of storage is that it can increase capacity without reducing selectivity. Thus, unlike in the case of drive-in or push-back racking, mobile racks allow direct access to every single deposited pallet. In addition, racks feature protective accessories and guided rails, which greatly reduces the risk of accidents and the loss of stock.

Mobile Racking: Uses and Advantages

There are several noteworthy advantages that recommend mobile racking over other storage solutions. These include:

Optimal use of space

Mobile racking systems require significantly less floor space to be installed and operated. Several aisles are removed per block of racks, while the racks are packed close together for high-density storage. As a result, double the pallets can be deposited using the same amount of space.

Full selectivity

Even though movable racking systems have a very high storage capacity, they remain 100% selective, which means that any pallet can be accessed directly at any time, without having to remove or move other pallets first.

FILO and FIFO access

All mobile rack storage systems can be customized to allow either FILO or FIFO inventory management. This is particularly important for warehouses that handle food and beverages, as well as other items with a very short shelf life.

Ideal for cold storage

Maintaining a cold warehouse can be an expensive affair, which is why managers will want to make the most of the available space. Mobile racking is a storage solution that combines space-efficiency and the possibility for FIFO access, which makes it perfect for controlled ambient temperatures.

Versatility

Mobile racking systems can emulate modular, pallet, and cantilever storage. As such, regardless of the type of racking you need, it is likely that you will be able to make it mobile in order to maintain its benefits and gain additional storage capacity.

Mobile Racking Systems: Drawbacks

When implemented in optimal circumstances, there are few, if any, disadvantages to moveable racking systems. This form of storage is not, however, suitable for all applications. Some issues to consider before implementing a mobile system in your warehouse are:

Versatility

Mobile racking systems are cost-effective in the sense that they allow you to use the same storage space to deposit additional inventory, as opposed to buying or renting more land. The initial investment for such a system, however, is higher than that required for selective racking, for instance.

Reduced height

Moveable racking systems can go up to 10m (or 30ft) in height, but most are shorter. This is significantly lower than other forms of storage, including selective and push-back racking. The loading capacity is also lower than normal selective pallet racks.

Limited aisle access

For maximum storage capacity, each block of racks is equipped with enough space for only one aisle. This means that, while driving a forklift, operators can only access one rack per block at a time. For multiple access, additional aisle space can be allocated per block.

Mobile Racking Systems from Kingmorack

Kingmorack designs, manufactures, and delivers a wide variety of durable racking systems for all types of warehouses and storages spaces. Our mobile racking systems observe the same high standards we apply to all our products. They are built using only quality materials and are therefore made to last through the wear and tear of frequent quotidian use.

Our years of experience in the racking industry have taught us that each project is unique and that each customer has specific demands. To discuss the details of your project and design the optimal mobile racking system for your warehouse, contact Kingmorack today.

Discuss your order

For more information, quotes, sample and orders, contact Kingmorack today.

Radio Shuttle Racks

Radio Shuttle Racks

Radio shuttle racks are similar to drive-in racking in the sense that they provide very high-density storage going several pallets deep. Unlike the latter, however, a radio shuttle system does not require the operator to drive into the racks to load and unload items.

Instead, this task is performed by a “radio shuttle” or “carrier” – a platform that can move across racks to retrieve and deposit pallets.

Basic Characteristics of Radio Shuttle Racks

Basic Characteristics of Radio Shuttle Racks

A radio shuttle racking system is a very high-density form of storage. Like drive-in racking, such a system can reach several pallets high, but unlike the latter, it can also go 30m to 60m deep (as opposed to only 20m). Requirements for aisle space are significantly reduced and the stability of the overall installation is higher due to the fact that operators needn’t drive inside the racks to load and unload pallets.

The heart of this form of storage is the “radio shuttle”, a special platform that is electrically powered and that can be moved using a remote control. To deposit a pallet, the operator must first place the shuttle on the correct lane using a forklift, then position the pallet on top of it, and finally command the shuttle to move its cargo to the back of the lane. The process is more or less identical when the operator must retrieve goods.

Radio Shuttle Racks: Uses and Advantages

Although radio shuttle racks are similar to drive-in counterparts, they present several additional advantages that set them apart from the latter. These include:

Increased stability and safety.

Because the driver of a forklift does not enter the racking system, they are no longer under any significant risk. The system itself is sturdier and more secure thanks to a structure that does not require aisle space.

Maximized storage capacity

Radio shuttle racks are the ultimate solution in terms of high-density storage. Racks can go up to 60m deep, which is more than is possible with any conventional form of racking. In the case of drive in racks, for instance, the lane is usually no more than 20m deep, because the forklift driver must drive into the aisle and it can be challenging for a person to drive very deep in a narrow space.

FILO and FIFO inventory management

Radio shuttle racks can be organized to suit both First-In-Last-Out and First-In-First-Out requirements. For the latter, pallets can be accessed at both ends of each lane.

Faster loading and unloading

A forklift operator must drive significantly less in order to retrieve or deposit a pallet. In addition, they are no longer required to maneuver the vehicle in very tight spaces, which would otherwise take up more time.

Ideal for cold storage

Inventory that requires special ambient conditions can be expensive to handle, which is why it is important to make the most of the available temperature controlled space. Radio shuttle racks are perfectly suited for this task.

Boltless racks from Kingmorack

If you’re on the market for a quality boltless rack that will endure the test of time and deliver on all of the benefits commonly associated with riveting shelving solutions, look no further than Kingmorack. Our experience in racking design and manufacture recommends us as a top choice.

When you purchase a boltless storage rack from us, you know you’ll get the versatility and ease of use that comes with bolt-free storage. If, for any reason, you’re not quite certain on the size and specifications of the boltless rack that best fits your storage, you can always give us a call and we’ll be happy to lend our assistance.

Discuss your order

For more information, quotes, sample and orders, contact Kingmorack today.