If your warehouse operations are expanding, yet your space is constricting you, there’s nothing more frustrating, especially in light of high rent and real estate prices. That means, in today’s modern world of warehouses, facility operators are getting more creative with pallet racking, and maximizing warehouse storage density.
So, if your operation is outgrowing its warehouse, this is the guide for you! We’ll dive deep into how to use pallet racks to your advantage and answer all the most frequently asked questions.
Keep reading to learn everything you need to know about maximizing your warehouse storage density.
Assessing Current Pallet Racking Systems
Maximizing how your pallet positions work is the simplest way to increase storage capacity. So, the first thing to do when considering switching up your pallet racking system is to assess your current layout.
To do so, start by mapping or drawing out the existing layout and measuring the vertical space utilization. Looking up, per se, is the best way to identify underused areas or inefficient configurations. Most often, warehouses increase their storage density by configuring their pallet racks vertically.
Assessing Inventory for Storage Density Improvements
The next part of the equation for maximizing storage density in your warehouse is evaluating the actual inventory. First, analyze your inventory turnover rates to determine if selective, drive-in, or push-back racking suits different product categories.
Here’s a quick guide to what types of inventory work best for each:
Selective Racking:
Ideal for: Fast-moving goods, diverse SKUs, items requiring frequent access
Best for: Products with high turnover rates, perishables, or when stock rotation is crucial
Examples: Retail goods, food and beverage items, pharmaceuticals
Drive-In Racking:
Ideal for: High-density storage of homogeneous products
Best for: Large quantities of similar items with low to medium turnover rates
Examples: Seasonal products, bulk non-perishable goods, construction materials
Push-Back Racking:
Ideal for: Medium-density storage with some product diversity
Best for: Items with moderate turnover rates, multiple SKUs of similar products
Examples: Beverages, canned goods, automotive parts
Lastly, pay attention to the potential of automated storage and retrieval systems (AS/RS) for high-density storage in facilities with sufficient ceiling height. Most importantly, when it comes to inventory is to follow the Pareto principle of placing the most critical 20% of your goods in the most accessible area (that has room for expansion and extra stock when applicable!).
How to Maximize Warehouse Storage Density
By systematically examining these factors, operators can uncover opportunities to increase their warehouse's storage density and operational efficiency significantly. To use vertical space, warehouses often install a shelf-supported mezzanine as a simple fix. Another consideration is implementing more narrow aisle racking or using double-deep systems.
Other common considerations that can be configured for a variety of inventory types and storage spaces include:
High-density storage solutions:
Drive-in/drive-through racking for bulk storage
Push-back racking for multiple SKUs in high-density areas
Optimized rack configuration:
Adjust beam levels to match product sizes
Use decking or wire mesh to store smaller items
Mixed-use strategies:
Combine different racking types to suit various product needs
Utilize cantilever racking for long or odd-shaped items
Pallet Racks FAQs
Before you go, let’s answer the most frequently asked questions about pallet racking for maximizing storage density.
What are the key considerations when reconfiguring pallet racking for storage?
Factors like the weight and dimensions of stored items, the layout of the warehouse, and the type of pallet racking system being used (e.g., selective, drive-in, push-back) are critical to consider during reconfiguration.
Is it possible to modify the height and width of existing pallet racks?
Yes, pallet racks can often be adjusted in height and width. However, it is essential to follow manufacturer guidelines to ensure safety and compliance with industry standards.
What safety precautions should be taken when reconfiguring warehouse storage?
Safety precautions include securing the area, using proper equipment, ensuring racks are not overloaded, and training employees on safe handling practices. Inspecting racks regularly for any signs of damage or wear is also crucial.
Do I need a professional service to reconfigure pallet racking, or can it be done in-house?
While some businesses may have the expertise to reconfigure racks in-house, hiring a professional service is often recommended to ensure safety and compliance with local regulations and to avoid potential damages or injuries.
What are the common types of racks, and which is best suited for my needs?
Common types include selective, drive-in, drive-thru, push-back, and pallet flow racks. The best type depends on the specific storage requirements, such as load capacity, inventory turnover, and available space.
Are there any regulatory requirements to consider when reconfiguring warehouse storage?
Yes, OSHA regulations and local building codes must be followed. Ensuring the racks comply with safety standards is critical to avoid fines and ensure employee safety.
What is the process for dismantling and reassembling racks?
The process typically involves unloading the racks, removing safety clips and beams, disassembling the frame, and then reassembling them in the desired configuration. All steps should be performed carefully to avoid damage to the racks or injuries to personnel.
How often should rack systems be inspected after reconfiguration?
It is recommended that pallet racks be inspected regularly, at least once every 6-12 months and after any significant changes or incidents, to ensure they remain in good condition and continue to meet safety standards.
What are the costs associated with reconfiguring racks?
Costs can vary depending on the complexity of the reconfiguration, whether professional services are needed, and any additional equipment or materials required. It is advisable to get a detailed quote before proceeding.
Can racks be moved to a different location within the warehouse?
Yes, racks can be relocated within a warehouse, but this requires careful planning to ensure structural integrity and safety. When moving racks to a new location, consider the weight of the loads and floor capacity.
The Final Word: Pallet Racks for Maximum Storage
With this guide, you now know how pallet racking can be used to maximize warehouse storage density. By re-structuring the way you store and manage inventory, you can maximize the use of space and improve operational efficiency.
Need help designing, purchasing, or installing pallet racks? Look no further than BMH. Our warehouse design services are essential for operations bursting at the seams of productivity and storage.
Our warehouse experts help you get the most out of your space — whether it's a simple 2D CAD drawing or a more complex problem such as inventory flow and pinch points. Virtually or in person! Get in touch to explore how BMH can improve your operations for maximum efficiency and increase your bottom line.
