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

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.

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