Various Types of Pallet Racking

There are multiple types of pallet racking and choosing the right one for your warehouse takes a lot of work. You have to consider the features, advantages, disadvantages, and cost implications of every pallet racking type. 

So, we’ve compiled this guide that offers detailed overviews of all major types of pallet racking systems. Hopefully, it’ll help you decide the right pallet racking for your needs.
Let’s get started!

Different Types of Pallet Racking

Here’s a list of all the different types of pallet racking that we’ll be covering in our guide:

1. Selective Pallet Racking
2. Double Deep Pallet Racking
3. Very Narrow Aisle (VNA) Pallet Racking
4. Drive-In & Drive-Through Pallet Racking
5. Gravity Flow Pallet Racking
6. Push-Back Pallet Racking
7. Pallet Shuttle Racking

Selective Pallet Racking

Approximately 60% of warehouses use selective pallet racking because of its versatility and ease of access. The beams are adjustable in 2-inch increments, allowing you to store pallets of varying sizes. Selective pallet racking can reach up to 40 feet and store up to 5,000 pounds per beam level.

But, you’ll have to compromise on a thing or two. 

The table below highlights the biggest advantages and disadvantages of a selective pallet racking system.

Best For

Selective pallet racking is best for:

• Businesses with high turnover products.
• Warehouses that require direct access to all pallets.
• Warehouses that store products of varying sizes.
• Warehouses that store large volumes of different SKUs.

Cost

Selective pallet racking is the least expensive out of all the pallet rack types, costing somewhere between $75 to $200 per pallet positioning.

Double Deep Pallet Racking

Think of double-deep pallet racking as a high-density version of selective pallet racking.

Double-deep pallet racking offers 50% higher storage capacity using two rows of adjacent racks. You’ll have fewer aisles and more racks to store pallets 2-deep. However, you’ll face retrieval limitations due to the double-deep build. 

Below are some more advantages and disadvantages of using double-deep pallet racking systems in warehouses.

Best For

Double-deep pallet racking is best for:

• • Warehouses that need high storage density.

• Warehouses that store large volumes of similar SKUs. 
• Businesses that use the FIFO (First In, First Out) method.
• Storing inventory that doesn’t require frequent access.

Cost

The initial cost of double-deep pallet racking is low compared to other high-density rackings. It costs somewhere between $80 to $200 per pallet positioning, mainly because of the straightforward design.

Very Narrow Aisle (VNA) Pallet Racking

As the name suggests, Very Narrow Aisle pallet racking uses narrow aisles, 6-foot width at most, to increase the number of racks in a limited space. Moreover, the thicker base allows for up to 50-foot-tall racks. This optimal utilization of the horizontal and vertical space provides 40% higher storage density as compared to standard pallet racking types.

However, a specialized forklift is needed to operate among the very narrow racking structure.

Read more advantages and disadvantages of using a VNA pallet racking system in the table below:

Best For

Very Narrow Aisle (VNA) pallet racking is best suited for:

• Warehouses with limited floor space. (Cold Storage Facilities)
• Distribution centers with high inventory turnover.

Cost

The wider and taller build requires a higher initial investment. The cost per pallet positioning ranges between $100 to $300.

Drive-In & Drive-Through Racking

Drive-In and Drive-Through pallet racking systems eliminate the need for aisles and provide high-density storage. Both these warehouse racking systems efficiently use all warehouse space to offer 75% higher storage density. 

The only difference is that Drive-In racking has a single entry and exit point and follows the LIFO (Last In, First Out) method while Drive-Through racking has separate entry and exit points and uses the FIFO (First In, First Out) method.

Here are a few more advantages and disadvantages of Drive-In/Drive-Through pallet racking:

Best For

Drive-In and Drive-Through pallet racks are best for:

• Warehouses with limited floor space.
• Warehouses that have slow/moderate inventory turnover.
• Storing large volumes of similar SKUs.
• Storing raw materials for longer periods.

Cost

Depending on pallet depth and safety features, a drive-in/drive-through pallet racking costs $200 – $400 per pallet positioning.

Gravity Flow Pallet Racking

Gravity Flow racking – also known as Pallet Flow racking – is a gravity-assisted palletized racking system. The racks are slightly inclined, and rollers move pallets from one end to the other where they can be unloaded. This semi-automated pallet racking system increases operational efficiency by 60% and significantly reduces labor costs.

Gravity Flow racking uses the FIFO (First In, First Out) method, making it a good fit for almost every industry. But, this system has a few caveats of its own. 

Check the table below to see the major pros and cons of a Gravity Flow pallet racking system.

Best For

Gravity Flow pallet racking system is best for:

• Fully-automated warehouses.
• Businesses using FIFO inventory management.
• Distribution and e-commerce fulfillment centers that require quick access to products.
• Retail and wholesale stores that require quick and automatic stock replenishment.

Cost

Gravity Flow racking is one of the costliest types of pallet racking. It costs $200 – $600 per pallet positioning.

Push-Back Pallet Racking

Push-back racking is a semi-automated pallet racking system that uses inclined racks to store pallets multiple deep and increase storage capacity by 25%. 

When new pallets are loaded into the rack, old ones get pushed back, hence the name push-back racking. As for unloading, old racks automatically roll forward when the front pallets are unloaded.

This warehouse racking system uses the LIFO (Last In, First Out) principle, making it ideal for low-turnover inventory. But, there are a few trade-offs to using this type of pallet rack system. See in the table below:

Best For

Push-back racking is best for:

• Cold storage units that require the highest possible storage density in limited space.

• Storing low turnover inventory.
• Warehouses that employ the LIFO inventory management method. 
• Warehouses that store large volumes of similar SKUs.

Cost

Much like Gravity Flow racking, the initial cost of a Push-back racking system is high. It costs between $200 to $500 per pallet positioning.

Pallet Shuttle Racking

The pallet shuttle racking provides the highest storage density out of all industrial racking systems by using deeper lanes and eliminating aisles. Automated shuttles, controlled via a remote tablet, transport pallets within the racking structure.

This automated pallet racking system reduces forklift traffic by 80%, limiting it to the front for loading and unloading. Scroll down to read the advantages and disadvantages of using a pallet shuttle racking. 

Best For

Pallet shuttle racking is the best type of pallet racking for:

• Controlled-temperature storage units and warehouses that require efficient use of limited space.
• Warehouses and distribution centers that handle large volumes of high turnover inventory.
• Warehouses that store the bulk of similar SKUs.

Cost

The pallet shuttle racking system costs between $200 to $600 per pallet positioning. The semi-automated nature and the technology involved are the main reasons for the high price.

Conclusion

Installing the right types of pallet racks in your warehouse is crucial for maximizing vertical space, increasing storage density, and improving accessibility. We hope our detailed guide helps you better understand the various types of pallet racking and you can finally choose a pallet racking system that will optimize inventory management in your warehouse. 

FAQs

1. What is the most common type of pallet racking?

Selective Pallet Racking is the most common pallet racking type. Due to its versatility, cost-effectiveness, and ease of access, a selective pallet racking system works well in all warehouses, regardless of the industry.

2. Is drive-in racking safe?

A drive-in racking system requires forklifts to drive into the racking structure to load/unload pallets. This increases the risk of forklift collisions with the pallet racking structure.

If you want to install a drive-in racking system in your warehouse:

• Train your forklift operators.
• Add safety features like guard rails, bumpers, and rack protectors. 
• Strictly follow weight limits to avoid structural collapses.

3. Can pallet racking systems be customized to fit specific warehouse layouts?

Yes, pallet racking systems can be customized to fit specific warehouse layouts. Pallet racking types like Selective Pallet Racking and Drive-In pallet racking have modular designs. Storage solution providers like OKE Storage can adjust beam lengths, upright heights, and column layouts to maximize warehouse space utilization.