What is warehouse racking?

Warehouse racking is the system of shelves, configuration, and location of the physical structure required to hold your inventory items. Typically made from plastic, metal, or wood, warehouse racking plays an important part in how easy it is to store and retrieve your inventory items as well as how efficiently your warehouse operates.

The Benefits of Strategic Warehouse Racking

Well-designed racks speed up operations and reduce errors. There are so many other benefits to strategic warehouse rack design, including:

• Space optimization: Stacking inventory or goods vertically on a rack maximizes available storage capacity. There’s no need to expand the warehouse’s footprint, either.

• Speed and accessibility: Vertical stacking may sound less efficient for employees, but racking systems are designed to be fast and accessible. With the proper setup, workers can quickly access and retrieve products during picking and restocking.

• Safety: A well-planned racking system reduces clutter and the risk of accidents. Most warehouse safety rules require features like secure frames and locking mechanisms to keep racks in place.

• Inventory and equipment optimization: Con your racking system to reduce waste by supporting inventory management methods like FIFO or LIFO. Rack organization also streamlines workflows for equipment like forklifts, helping you make the most of warehouse machinery.

• Reduced costs: Warehouse racking minimizes the need to purchase additional storage space, reducing real estate costs. It also speeds up fulfillment accuracy and speed, and improves equipment utilization.

Warehouse Racking Types

Embracing warehouse racks will maximize storage space, but not all businesses follow the same racking system or fulfillment processes. There are several warehouse racking system configurations, each with pros, cons, and unique use cases.

Selective Racks

The most commonly used pallet system, selective racks provide access from an aisle. These warehouse racking systems are ideal for narrow aisle racking, standard systems, and deep-reach systems.

However, selective racks require narrow lift trucks and only accommodate a single pallet in depth. Still, they’re ideal for warehouses with a mix of SKUs and high turnover, where employees need selective access to individual pallets.

Pros

• Highly accessible because they offer direct access to each pallet

• Versatile options for a wide range of SKUs

• Quick to install, recon, or expand

Cons

• Less dense storage capacity compared to drive-in or flow racks

• Requires narrow aisle lift trucks

Drive-in and Drive-Through Racks

Drive-in racks and drive-through racks are ideal for high-density storage and often go from floor to ceiling. Constructed of durable steel, these warehouse racking systems offer enough space for a forklift to move into each bay. It’s important to note that drive-in racks have one entrance and exit, but drive-through racks allow access on both sides of the bay.

As a result, drive-in racks are suited to the last in, first out (LIFO) process commonly used for nonperishable products. On the other hand, a drive-through system requires a first in, first out (FIFO) process.

Cold storage facilities frequently use these racking systems to store perishable goods in high-density storage. However, they’re also popular in industries like manufacturing, where businesses need to store lots of raw materials.

Pros

• Maximizes space for bulk storage

• Reduces square footage for storing large quantities

• Efficient inventory rotation for perishable goods

Cons

• Less effective for warehouses with SKU variety

• Limited to LIFO and FIFO strategies

Push Back Racking Systems

Typically used for bulk storage, push back racking systems store products that span two to five pallets. When employees load a pallet onto the system, it pushes the next pallet back. When employees unload a pallet, it goes to the front of the rack.

Push-back racking systems utilize the LIFO system, often featuring inclined rails, sliding carts, and double lanes. This warehouse racking strategy is ideal for storing bulk items for retail. It’s also popular in warehouses that need rapid access to products.

Pros

• Optimizes space with high-density storage

• Efficient loading and unloading

• Ideal for bulk storage without strict rotation needs

Cons

• Limited capacity for rotating inventory

• More expensive because of its design and inclined rails

Flow Racks

Also known as gravity racks, flow racks are popular for high-density storage. Flow racks use gravity rollers that move with the rack load and feature brakes or speed controllers to regulate item movement.

With this type of warehouse racking system, employees load items at the higher end and remove them at the lower end with a FIFO system. Product rotation happens automatically, as the racks flow with each load. One advantage of flow racks is that they don’t require electricity because gravity powers them.

Flow racks are common in distribution centers, food and beverage industries, and warehouses where strict inventory rotation is critical. They’re ideal for high-volume, fast-moving warehouses with rapid stock turnover.

Pros

• Doesn’t require electricity

• Automatically rotates inventory

• Streamlines picking and replenishment

Cons

• Higher cost due to rollers and braking systems

• Works best with uniform product sizes and weights

• Complex installation

How To Choose The Best Warehouse Racks

Cost

High-density racking systems, like flow or drive-in racks, may have a higher upfront cost, but can maximize storage space and potentially reduce costs associated with additional warehouse space. On the other hand, selective racks are less costly to install and recon, but offer lower-density storage.

Available Floor Space

The amount of floor space in your warehouse plays a significant role in choosing a racking system. High-density racking systems, such as drive-in or push back racks, can store more products in a smaller footprint, making them ideal for warehouses with limited floor space.

Ceiling Height

Racking systems like selective or flow racks allow storage up to the ceiling, maximizing your available cubic space. When planning, consider your building’s ceiling height, ensuring that your chosen racking system and forklifts can accommodate high stacking.

Pallet Type and Size

Some racking systems may require consistent pallet sizes for proper operation, such as flow racks that rely on uniform dimensions to move items smoothly. Make sure your chosen racking system aligns with the type, size, and dimensions of your inventory pallets.

Frequency of Pallet Access

Warehouses with high inventory turnover and frequent pallet access benefit from selective racking, or flow racks, because they support quick retrieval. In contrast, push back and drive-in systems are better for bulk storage with lower turnover and less frequent access.

Number of Pallets To Be Stored

High-density systems such as drive-in or push-back racking are designed for large quantities of pallets with limited access points, while selective racking is better for smaller quantities with a higher focus on accessibility.

How To Install Warehouse Racks Safely

Designing an effective warehouse rack is crucial, but installation is just as important as design. Follow these tips to minimize accidents and ensure safety during warehouse rack installation:

• Plan the layout: Measure your warehouse space, ceiling height, and floor plan. Consider traffic flow for workers and forklifts. Outline where each rack will go, considering aisle widths, emergency exits, and forklift access. Also, make sure the installation plan complies with local building codes, fire safety regulations, and industry standards.

• Check your floor: Ensure the warehouse floor is level, stable, and capable of bearing the load of racks and inventory. If the floor can’t support the weight, strengthen it with anchor points.

• Follow manufacturer instructions: Carefully follow the manufacturer’s instructions for assembly and installation. Secure all beams and crossbars using locking pins or clips to prevent dislodging during use. Ensure all beams are at the correct height and level to avoid uneven loading.

• Consider additions: They aren’t a requirement, but additions like wire mesh decking can prevent small items from falling off tall shelves. Backstops also prevent pallets from falling off the back of the racking system.

• Test rack loads: Verify that each rack section can support the intended load without bending or collapsing. Ensure your team distributes the weight by placing loads evenly across beams.

• Label clearly: Clearly label each racking system with its maximum load capacity to ensure workers don’t overload them. Display safety signage that outlines proper loading and unloading procedures and weight limits. Go with Camcode’s durable warehouse rack labels to ensure long-term legibility in even the harshest conditions.