5 Must-Have Features in a selective pallet racking
5 Factors to Consider When Choosing a Warehouse Pallet Racking ...
Choosing the right warehouse pallet racking system is crucial for any business that needs to store and organize large quantities of inventory. There are many factors to consider when selecting a pallet racking system, such as the type of products being stored, the amount of space available, and the budget for the project.
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In this article, we will explore five key factors to consider when choosing a warehouse pallet racking system, including the different types of racking available, the cost of installation, the best methods for organizing warehouse shelving, whether to purchase new or used racking, and how to safely and securely install pallet racking in your warehouse.
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#1 Which Pallet Racking Types Work for My Business’ Needs?
Selective racking, drive-in racking, push-back racking, and pallet flow racking are some of the different types of pallet racking systems available. Each system has a distinctive design and purpose.
1. Selective Pallet Racking
Selective pallet racking is a type of storage system often used in warehouses and distribution centers. This system utilizes vertical frames to support horizontal beams that carry individual pallets. One of the benefits of selective pallet racks is their accessibility, allowing for efficient loading and unloading of products. They also offer flexibility, as they can be easily adjusted and reconfigured to accommodate changes in inventory. Additionally, selective pallet racking is a cost-effective option compared to other storage solutions.
2. Drive-in Pallet Racking
Drive-in pallet racking, on the other hand, provides high-density storage by utilizing rails that extend deep into the racking system. Forklifts can drive into the system to load and unload pallets, making it easy to access products. This type of racking system is also cost-effective for businesses that need to store large quantities of the same product. The proximity of the upright frames and the rails creates a space-saving solution that maximizes the use of available floor space.
3. Push-back Pallet Racking
Push-back pallet racking allows for multiple pallets to be stored on a single lane, with each pallet being pushed back as a new pallet is added. This is made possible by using carts that move on inclined rails. This type of racking system also offers high-density storage and is more accessible than other types, allowing for easier picking and restocking of inventory.
4. Pallet Flow Racking
Pallet flow racks utilize gravity to move pallets along rollers or wheels from the back of the rack to the front. This is particularly useful for businesses that need to manage inventory on a first-in, first-out basis. Pallet flow racks also offer high-density storage and better accessibility, as each lane can be independently accessed.
#2 How Much Does Warehouse Pallet Racking Cost?
Material, construction, size, capacity, installation, and labor costs determine a racking system’s cost. Let’s dive deeper into these costs:
Construction
The type, size, and materials of a racking system determine its material and construction costs. Steel is the most prevalent racking system material, and its cost depends on quality and thickness. High-quality steel and heavier materials make racking systems last longer but cost more.
Racking System Capacity
Cost also depends on racking system size and capacity. Higher-capacity racking solutions cost more. Custom-designed racking systems may cost more owing to design and engineering.
Installation
The complexity and experience of the installation team determine racking system installation and labor expenses. Drive-in racking systems may require more labor to install than selected racking systems. Installation team experience and expertise also affect cost.
Racking Systems Costs
As said, racking system costs vary. Selective, drive-in, push-back, and pallet flow racking prices for warehouses are approximately:
Selective
Selective racking costs depend on system size and capacity. A $10,000-lb per-level selective racking system costs $75 to $200 per pallet slot.
[Client estimated pricing required]
Drive-In
Drive-in racking systems cost more than selected racking due to their higher storage density. Drive-in racking systems with 10,000 lbs per level costs $200 to $500 per pallet spot.
[Client estimated pricing required]
Push-Back
Due to their higher storage density and design complexity, push-back racking systems cost more than selected ones. Push-back racking systems with 10,000 lbs per level costs $200 to $400 per pallet position.
[Client estimated pricing required]
Pallet-Flow
Pallet flow racking systems cost more than selected racking due to their higher storage density and design complexity. A 10,000-lb-per-level pallet flow racking system costs $200 to $400 per pallet slot.
[Client estimated pricing required]
#3 How Can I Best Organize Warehouse Shelving?
Organizing a warehouse with selective, drive-in, push-back, and pallet flow racking systems requires careful planning and consideration of various factors such as product type, frequency of access, and storage capacity. Here are some tips to best organize your warehouse shelving:
1. Categorize Products
Categorize your products based on their type, size, and frequency of access. This will help you determine which racking system is best suited for each type of product.
2. Use Labels
Use labels to identify each product’s location within the racking system. This will help improve organization and make it easier to locate products when needed.
3. Consider FIFO
If your warehouse deals with perishable products, consider implementing a first-in, first-out (FIFO) system. This means that products with an earlier expiration date are stored in front of those with a later expiration date, ensuring that products are used before they expire.
4. Maximize Storage Capacity
To maximize storage capacity, consider using vertical space by stacking pallets as high as possible. However, make sure to follow safety guidelines and use appropriate equipment to prevent accidents.
5. Keep High-Demand Products Easily Accessible
Ensure that high-demand products are easily accessible by storing them at the front of the racking system or in a separate racking system altogether. This will help improve efficiency and reduce the time required to locate and retrieve products.
6. Monitor Inventory Levels
Regularly monitor inventory levels to ensure that products are being restocked as needed. This will help prevent stockouts and ensure that products are always available when needed.
7. Regularly Inspect the Racking System
Regularly inspect the racking system for any signs of damage or wear and tear. Damaged racking systems can pose a safety hazard and should be repaired or replaced immediately.
#4 Should I Buy New or Used Warehouse Racking?
Consider price, storage needs, and racking condition when choosing new or secondhand warehouse racking. Here are five considerations for choosing between new and used warehouse racking:
1. Budget
Budgeting is key. For organizations on a tight budget, used racking systems may be the preferable choice due to their lower cost.
2. Storage Needs
Consider the type of products you will be storing and how much storage space you require. If you need a racking system with specific features, such as high-density storage, a new racking system may be the better option. However, if you have more basic storage needs, a used racking system may suffice.
3. Condition of Racking
Buying used racking systems requires a comprehensive inspection. Check the racking for wear, corrosion, and degradation that could compromise its stability. Cost reductions may be possible if the storage system is undamaged.
4. Safety Considerations
Safety is paramount when it comes to warehouse racking systems. New racking systems often come with updated safety features, such as anti-tip devices and seismic bracing, which may be necessary depending on your location and industry regulations. Used racking systems may not have these safety features, so it is important to ensure that any used racking you purchase is up to code and meets safety standards.
5. Warranty & Support
New racking systems often come with warranties and support from the manufacturer, which can provide peace of mind. Used racking systems may not have these same warranties and support options, which can be a consideration when making a purchase.
#5 How Do I Securely & Safely Install Warehouse Pallet Racking?
Installing warehouse pallet racking securely and safely is critical for ensuring the safety of warehouse workers and the integrity of the racking system. Here are some steps to follow to ensure secure and safe installation of warehouse pallet racking:
1. Obtain Permits and Approval
Before installing a pallet racking system, check with local authorities to ensure that you have obtained all necessary permits and approvals.
2. Follow Manufacturer Instructions
Follow the manufacturer’s instructions for installing the pallet racking system. Make sure to read the instructions carefully and understand all the steps involved.
3. Prepare the Site
Prepare the site by ensuring that the floor is level and clean. Any unevenness in the floor can cause the pallet racking system to be unstable, which can pose a safety hazard.
4. Assemble Uprights
Assemble the uprights of the pallet racking system according to the manufacturer’s instructions. Make sure to use appropriate tools and equipment and ensure that all bolts and screws are tightened securely.
5. Install Beams
Install the beams of the pallet racking system according to the manufacturer’s instructions. Make sure to level the beams and ensure that they are securely attached to the uprights.
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6. Securely Anchor the Racking System
To ensure the stability of the racking system, securely anchor it to the floor using appropriate anchors. Make sure to follow the manufacturer’s instructions for anchoring the racking system and ensure that the anchors are suitable for the type of flooring.
7. Inspect the Racking System
After installing the pallet racking system, each component must be inspected for secure connections, damage, and excessive wear and tear. Checking the shelf system often will ensure its longevity.
8. Train Workers
Workers must be trained on how to load and unload pallets, utilize safety gear, and report system damage or instability.
Key Takeaways
Selective, drive-in, push-back, and pallet flow racking are different types of pallet racking systems available for warehouses and distribution centers.
- Selective racking provides accessibility and flexibility at a cost-effective price.
- Drive-in racking offers high-density storage with easy access to products.
- Push-back racking allows for multiple pallets to be stored on a single lane.
- Pallet flow racking utilizes gravity for first-in, first-out inventory management.
Each type of racking system has its distinctive design and purpose.
Organizing a warehouse with selective, drive-in, push-back, and pallet flow racking systems requires careful planning and consideration of various factors such as product type, frequency of access, and storage capacity.
To best organize your warehouse shelving, you should categorize products, use labels, consider FIFO, maximize storage capacity, keep high-demand products easily accessible, monitor inventory levels, and regularly inspect the racking system. These tips will help improve organization, reduce inefficiencies, and ensure the safety of warehouse workers.
The cost of a racking system depends on its type, size, capacity, materials, installation, and labor. Selective, drive-in, push-back, and pallet flow warehouse racking systems cost differently. When choosing a racking system, analyze your business’s demands and engage with experts to get the finest one.
When choosing between new or secondhand warehouse racking, consider factors such as budget, storage needs, and the condition of the racking. Used racking systems may be a better choice for organizations with a tight budget, but it is important to inspect them carefully for wear and damage that could affect their stability.
The installer must plan and follow the manufacturer’s instructions to build the warehouse’s pallet racking correctly and safely. If you follow these standards, your warehouse personnel will be safe and your racking system will be built properly.
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9 Things to Consider When Designing a Pallet Racking System
The first step in designing a new pallet racking system is to understand the workflow, capabilities, and limitations of your warehouse.
Have you been charged with developing your facility’s pallet racking system and don’t know where to start? Are you moving into a new building and need help designing a storage solution for your warehouse?
In our extensive experience working with customers from all industries, we find that customers sometimes will spend time trying to design their pallet racking device before meeting with us. While it never hurts to come into a meeting with additional information, we find that using a team of experts from the start can help save valuable time for you and your business while ensuring that you get the best solution to suit your warehouse.
Not only can we provide a pallet racking design for your facility quickly, we also have the requisite resources to ensure that our design is correctly engineered and complies with industry standards and regulations. Understanding how each of these aspects apply to your facility will help you get primed, trained and comfortable to go into your first consultation on the design of your pallet racking system.
9 Things to Consider When Designing a Warehouse Pallet Racking System
Continue reading for 9 things you need to learn about the operation, strengths and drawbacks of your warehouse when designing a new pallet racking system.
1. Pallet Size and Type
The weight and measurements of the pallets (length, height, width) are important measurements to be aware of when designing a pallet racking system . For most applications the industry standard pallet size (40 “x 48”) is a perfect fit. The size of the pallet will help determine system dimensions such as the depth and height of the uprights.
The type of palletized items will influence the type of pallet racking system required if the items:
- Need specific environmental conditions
- Are fragile and cannot be stacked
- Are date-sensitive / have expiration dates
2. Order of Inventory Retrieval: LIFO vs FIFO
Whether your system requires inventory retrieval by LIFO (last-in-first out) or FIFO (first-in-first-out) is crucial in deciding the type of storage and pallet rack solutions needed. If your goods are date-sensitive, you’ll probably need a system that enables the longest in stock products to be delivered first-FIFO. If your product’s shelf life isn’t date-sensitive, a LIFO program can be used to maximize warehouse space.
3. SKU / Pallet Count
The number of SKUs in a facility and the number of pallets per SKU play a major role in deciding the type of pallet racking system you may need. In applications where there is only one pallet per SKU, selective pallet racking can be used as it enables flexibility for SKUs thus making them readily available.
Facilities with multiple pallets per SKU may want to use a higher density storage system, such as drive-in or push back pallet racking. Facilities with a high number of pallets per SKU that also involve FIFO retrieval of inventories may consider investing in a pallet flow racking system.
4. Warehouse Environment
The cost of your racking system will fluctuate according to the type of environment your products require. Things can be stored in a variety of different situations, including:
- Cold temperature (freezer or cooler)
- Controlled temperature
- Ambient temperature (material does not need a particular temperature)
Ambient environments are where temperature in the factory is not a critical factor in maintaining product integrity. Cold warehouse environments typically store food or other perishable items at low temperatures, Whereas temperature-controlled warehouses often store items such as drugs, tobacco, etc. where temperatures are kept within an acceptable range to maintain the integrity of products.
Predictably, conditions where temperature isn’t critical will cost less. Typically, pallet racking systems are most costly in a cold environment since they require:
- Long installation-installers cannot spend long periods in a freezer
- Strategic set-up-since refrigerator / freezer storage space costs more, strategic planning is needed to ensure storage space is maximized
- Food grade conditions-since cold warehousing environments usually store food items, certain FDA compliance criteria are required. Pallets holding food items, for example, must be kept at least 12 inches off the ground
5. Building Structure
Whether a pallet racking system is constructed as an improvement to an existing building or installed in a newly built building may impact the budget of the project, schedule, available warehouse space and more. Certain important considerations relating to the building structure include:
- Column spacing – you need to be conscious of where the support columns are and how they are separated from each other in order to “bury” them in the gap between back-to-back rows of racking
- Internal ceiling height – this will tell us how tall the uprights and beam levels can be
- Location and measurements of dock doors
- Usable warehouse space
6. Product Flow / Accessibility Requirements
Slow-moving products as well as fast-moving products occur in every warehouse. It’s important to know which of the products have a faster turnaround period and need to be more frequently accessed. Knowing how this can impact the design of your system will help maximize the retrieval time, particularly for products with a quick turnaround time.
Data on product flow and accessibility can also help to decide which SKUs to store closer to the shipping and receiving areas, and whether you may need high-density storage for some SKUs and more flexible storage for others.
If your facility often has large orders with an almost immediate turnaround time, setting up a staging area near the shipping doors for temporary storage of those products is a good idea.
7. Material Handling Equipment in Your Facility
The type of material handling equipment (forklift, lift truck, or man-up order picker) used to collect pallets in your warehouse and its size is critical for determining the width of the aisle and the number of racking rows that will fit into a facility.
For example, an industry standard 12-foot aisle would be required if you’re using a standard counterbalance forklift, whereas man-up order pickers can maneuver through much narrower aisles. It is desirable to construct a warehouse with the aisles as narrow as possible, as this enables maximum storage space.
8. Seismic Activity
Whether your facility is in an area with frequent / severe seismic activity or not can impact the type of material and support that a system will need. If your facility is in an area with high seismic activity, higher gauge steel (sometimes structural steel is needed, as roll-formed steel is weaker), wider / larger footplates and additional anchor reinforcements may be required for the pallet racking system. Basically, the more seismic activity in your area, the more structural integrity your system will need for seismic movement to handle, which will increase the cost of your racking system.
9. Understanding Your Budget and Acceptable ROI
New vs. Used Pallet Rack Systems
“What about used pallet racking?” This is a question we get asked frequently. While used systems can save you some upfront costs, in the long run they usually end up costing more, because:
- Their structural integrity is uncertain
- A third-party structural engineer is needed to review and approve existing structures which is an expensive service
- They are not customized to match the products, workflows or needs of your facility.
In short, going with a used pallet racking system is a riskier option. By making the investment for a new system up front you will receive a system with the following advantages:
- Uncompromised structural integrity
- Guaranteed to pass permit inspection
- Tailored to the needs of your facility
The Type of Pallet Racking System
Some types of pallet racking systems have more features and capabilities than others, and therefore, are more expensive. Selective pallet racking is the most cost-effective option, with the shortest lead time. So, if your facility doesn’t actually require high-density storage, selective pallet racking may be the best option for you.
However, if higher density storage is needed, depending on your circumstances you may need to use drive-in pallet racks, push back pallet racks or even pallet flow racking.
Utilizing a Team of Professionals
As mentioned above, utilizing a team of professionals to design your pallet racking system is the best way to ensure that your system is:
- Designed quickly and efficiently
- Engineered according to industry standards and regulations
- The best solution for your facility
Conclusion
We hope this article has helped you understand the pallet racking needs of your facility and become more comfortable having an informed talk with a specialist. In conclusion, the 9 things to consider when designing a warehouse pallet rack system are:
- Pallet size and type
- Order of inventory retrieval
- SKU / pallet count
- Warehouse environment
- Building structure considerations
- Product flow / accessibility requirements
- Material handling equipment in your facility
- Seismic activity
- Understanding your budget and acceptable ROI
Our team of Warehouse Design Specialists are dedicated to providing complete, custom designed pallet racking systems and other industrial systems. Our experts will meet with whomever supervises your facility to ensure we get every detail needed to design your pallet racking system effectively.