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.

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