What is Pallet Racking?

Maximizing vertical space usage, streamlining inventory management, and increasing the efficiency of the entire warehouse are just a few things a pallet racking can do. But, what is pallet racking exactly? Read along as we try to answer this question.

Along with discussing the benefits and major industrial applications of pallet racking systems, we’ll also briefly discuss the core components and the various pallet racking types. 

What is Pallet Racking?

Pallet racking is an inventory-handling system that stores palletized goods on a vertical structure made out of metal uprights and beams. These components form racks/shelves and pallets loaded with goods and inventory are stored in this vertical structure. Inventory can then be loaded/unloaded using a forklift as and when needed.

This vertical structure utilizes vertical space and provides high-density storage in limited-floor area warehouses. It’s a versatile and efficient storage system that has countless industrial applications. We’ve discussed some major use cases in detail in the later sections of this article. 

For now, let’s take a closer look at the various components of a pallet racking system so you can better understand its structure and functionality.

Benefits of Pallet Racking

Figure 1 - Pallet Racking System

Regardless of the industry and applications, pallet racking has FIVE major benefits. Here’s a quick look at all of them:

  • Increase Storage Capacity: With a pallet racking system installed, warehouses and businesses finally put the vertical space to use to massively boost their storage capacity.
  • Streamline Inventory Management: A pallet racking system streamlines all of your inventory storage and retrieval operations. The pallet racking structure and its inventory organization increase the operational efficiency of the whole warehouse.
  • Versatile Storage Solution: As your storage needs change over time, you won’t have to completely disassemble a pallet racking system and install a new one. Simply rearrange and upgrade adjustable components like the uprights and beams as per your needs.
  • Reduces Inventory Damage: Once you install a palletized racking, your inventory finally gets a designated and safe storage space. It reduces inventory damage and accidents in the workspace.
  • Reduces Manual Labor Cost: An efficient pallet racking system minimizes the need for extensive manual labor. You can save a lot of money in the long run due to decreased manual labor costs.

As you narrow down to specific industries and applications, you’ll find plenty more benefits of using a pallet racking system for storage and inventory management. 

Figure 2 - Pallet Racks

Types of Pallet Racking

There are various types of pallet racking. You should always install a pallet racking system that best suits your warehouse layout and best fulfills your storage needs. Below are the SEVEN major pallet rack types:

  • Selective Pallet Racking: Due to high selectivity and low installation cost, selective pallet racking is the most widely used pallet racking system. It allows direct access to every rack for quick and easy loading/unloading.
  • Double Deep Pallet Racking: High storage density and easily upgradeable in case of future expansions. However, you’ll be limited to the LIFO (Last In, First Out) inventory management method.
  • Very Narrow Aisle (VNA) Pallet Racking: For a higher initial cost, you get up to 40% higher storage density because VNA palletized racking utilizes maximum floor and vertical space for storage.
  • Drive-In & Drive-Through Pallet Racking: 75% higher storage density than every other pallet racking system because of no aisles. If you have limited floor space, a Drive-In or Drive-Through pallet racking system is a great option. 

Figure 3 - Pallet Racking

  • Gravity Flow Pallet Racking: Another high-density pallet racking type that doesn’t use aisles and instead uses a gravity-assisted mechanism for easy inventory access. However, it is one of the costliest pallet-racking systems.
  • Push-Back Pallet Racking: A semi-automated, high-density storage system that uses inclined racks to automate pallet movement. It is not good for storing high turnover inventory.
  • Pallet Shuttle Racking: A remote-controlled pallet racking system that offers the highest storage density and minimizes forklift traffic in your warehouse. However, it costs up to $600 per pallet positioning. 

Core Components of Pallet Racking

Figure 4 - Core Components of Pallet Racking

FOUR core components combine to create a durable and functional pallet-racking structure. Here’s a quick look at each.

  • Uprights: The vertical frame of a pallet racking is called an Upright. Securely bolted to the warehouse floor, these uprights are the backbone of a pallet racking system. Every other component is built around these upright frames. Base plates and floor anchors are used to secure uprights to the floor and add extra stability.
  • Beams: Also known as Crossbars, beams are horizontal bars attached to the upright frames and create racks/shelves where the palletized goods are stored. Beam connectors and safety pins are used to securely attach and lock beams to upright frames.
  • Cross Bracing: Cross bracing is an essential component that adds extra stability and support to a pallet racking system by attaching diagonal bars to the uprights.
  • Wire Mesh Decking: Mesh wire decking is attached to the beams to prevent pallets from falling through the gaps. Pallet support bars are also used for the same purpose.

Other important components of pallet racking include proper signage, column protectors, and frame bars. 

Depending on the type of pallet racking, the number of components can vary but these core components remain the same.

Applications of Pallet Racking

Figure 5 - Applications of Pallet Racking

Pallet racking can be used in various industries, warehouses, and even in retail store back rooms. Below are the THREE main applications of pallet racking.

  • Warehouses & Other Storage Facilities: Large warehouses have plenty of vertical space that goes unused. Warehouse pallet storage racks can put that vertical space to use and massively increase the storage density of any warehouse. A pallet racking system is great for retail store backrooms and temperature-controlled storage facilities. 
  • E-commerce Fulfillment & Distribution Centres: Pallet racking is perfect for big distribution centers and e-commerce fulfillment centers. Along with organizing and managing large bulk inventory, a pallet racking system also improves the operational efficiency of these fulfillment and distribution centers. 
  • Manufacturing Facilities: Industrial warehouse racks can help manufacturing facilities better manage their incoming raw material and outgoing finished goods. This applies to the processed foods industry, the automotive parts industry, and many more manufacturing industries.

Conclusion

Installing a pallet racking system for a warehouse/business is a costly affair and you don’t want to make hasty, uninformed decisions. Hopefully, after going through our guide, you now have an idea of what is pallet racking, what its applications are, and how storage facilities, warehouses, and businesses benefit from a pallet racking system.

FAQs

1. What is the purpose of pallet racking in a warehouse?

Increase the storage capacity of warehouses that have limited floor space. A pallet racking system uses the vertical space of a warehouse to increase storage density and inventory management. 

2. How do I choose the right pallet racking system for my needs?

To choose the right pallet racking system for your business, you should consider your:

  • Storage requirements.
  • Type of inventory.
  • Warehouse layout.
  • Budget.

If you can’t find the perfect pallet racking system, you can also ask your pallet racking supplier to create a custom pallet racking system for your warehouse. 

3. How long does pallet racking last?

With proper installation and regular maintenance, a pallet racking system can last up to 20 years. However, forklift accidents, poor maintenance, and low-quality material can result in a shorter lifespan for your pallet racking.

4. Is pallet racking expensive to maintain?

No. Regular pallet racking maintenance is not costly. However, ignoring the signs of wear and tear and not investing in pallet racking maintenance at all can result in damaged components. Replacing those damaged components is a lot more expensive than regular maintenance and checks.

Scroll to Top