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When scoping out what your options are for a warehouse pallet racking solution, maximising the floor space and efficiency will be one of your key priorities, as every square foot of your warehouse holds potential for increased productivity and saving costs. Among the many pallet storage solutions available, narrow aisle pallet racking stands out as a popular choice for businesses looking to make the most of their storage space. However, whilst this type of system reduces the aisle widths to create space, we need to explore if its’ right fit for your warehouse?

Narrow aisle pallet racking is a pallet racking system which reduces the width of the aisles between the racks by as much as 50% compares to that of traditional rack  configurations.  Unlike traditional wide aisle setups, narrow aisle racking utilises specialised forklifts or reach trucks capable of navigating tighter spaces to put away and pick the pallets. This design enables warehouses to store more inventory while maintaining accessibility to individual pallets.

Narrow aisle racking has significant advantages when it comes to maximising the floor space within your warehouse with up to a 50% improvement compared to traditional racking systems. Additionally, the design of narrow aisles facilitates faster movement of goods throughout the warehouse, enhancing material handling efficiency and leading to quicker order fulfillment times. Despite the narrow aisles, accessibility to individual pallets is maintained, ensuring enhanced selectivity crucial for warehouses managing diverse product lines or frequently changing inventory. This efficiency in retrieving specific items contributes to smooth operations adaptable to varying demand patterns. Moreover, the system’s space optimisation capabilities translate into long-term cost savings as warehouses minimise the need for costly expansions or off-site storage solutions. By utilising existing space more effectively, businesses can improve financial efficiency and sustainability over time.

While narrow aisle pallet racking offers numerous advantages, it’s essential to consider potential disadvantages before implementing this storage solution.

Narrow aisles require special forklifts or reach trucks capable of maneuvering in tight spaces. These vehicles typically come with higher upfront costs compared to standard forklifts. Additionally, their maintenance and operation may require specialised training for warehouse staff, adding to operational expenses.

Whilst narrow aisle racking will maximise your space, it may not be a suitable option for the types goods you are storing as some products may require wider aisles or alternative storage solutions to ensure efficient retrieval and handling. Additionally, the restricted space may pose challenges for certain material handling tasks, particularly those involving oversized or irregularly shaped items.

The initial upfront costs of narrow aisle pallet racking could be higher as it involves for both equipment and infrastructure modifications. These expenses may include purchasing specialised forklifts, retrofitting existing racking systems, and potentially redesigning warehouse layouts. While the long-term benefits of improved space and efficiency may outweigh these initial costs, businesses must carefully evaluate the return on investment before proceeding with implementation.

Choosing the right pallet racking system can be difficult, so by contacting the team a Stamina Storage Systems, we can discuss the various options available. We will arrange a free site visit to help guide you on the right solution for your business, To speak to our team, or arrange a free site visit, get in touch today.

Pallet racking systems are the backbone of countless warehouses and distribution centers around the world. These versatile structures provide efficient storage solutions for palletised goods, optimising space and facilitating smooth operations. In this comprehensive guide, we’ll delve into the intricacies of pallet racking, covering everything from its components to different types and how to choose the right racking system for your needs.

Pallet racking is a storage system designed to store palletised goods in a warehouse or distribution center. The system, consists of  upright columns, horizontal beams, and optional accessories such as wire or timber decking. The primary purpose of pallet racking is to maximise vertical storage space while allowing easy access to stored items for loading and unloading using forklifts or other handling equipment.

There are various types of pallet racking systems available, which we will discuss below.

Before we dive into the various types of pallet racking, let’s first understand the key components that make up these systems:

Pallet racking systems can broadly be categorised into two main types based on their accessibility and storage density:

• Adjustable Pallet Racking(APR): This is the most common type of direct access pallet racking. It allows for individual pallets to be accessed directly without moving others. Selective racking systems are versatile and suitable for warehouses with a wide variety of SKU (stock-keeping unit) requirements. They offer easy access to each pallet, making them ideal for businesses that prioritise quick retrieval of goods.

• Cantilever Racking: a specialised type of pallet racking system designed primarily for the storage of long, bulky, or irregularly shaped items that cannot be stored on traditional pallets. Unlike conventional pallet racking, which utilises horizontal beams to support pallets, cantilever racking features long, horizontal arms that extend from vertical columns.

• Mobile Racking Systems: Unlike traditional static pallet racking, mobile pallet racking is mounted on a steel framed base. This racking system is installed over guided mobile bases that slide laterally, thus eliminating the need for aisles, which open up only when accessed.

• Drive-In Racking: Drive-in Racking, also know as drive-through racking, allows forklift trucks to drive directly into the pallet racking , providing easy access to stored pallets. This efficient design eliminates the need for aisles between racks, maximising storage space for products with a low inventory turnover rate.

• Push Back Racking: Push back racking is a type of selective pallet racking system used in warehouses to maximise storage density while maintaining selectivity and ease of access to stored goods. Ideal if you’re storing bulk goods on pallets according to the Last-in, First-out (LIFO) principle.

• Carton Flow Live Shelving: This system utilises gravity to move products seamlessly from the loading end to the picking end, reducing the need for manual handling and increasing picking efficiency and is particularly effective for products with a short shelf life, where the first-in-first-out (FIFO) system is crucial. It’s commonly used for cartons, boxes, and smaller items.

When it comes to choosing a pallet racking system for your warehouse or distribution centre, several considerations come into play. First off, you’ve got to assess your storage requirements. Take a good look at the size, weight, and volume of your inventory, including any items with special handling needs. This will help determine the type of racking system that can best accommodate your goods.

Accessibility is another key factor to think about. Do you need direct access to each pallet, or are you okay with sacrificing a bit of accessibility for higher storage density? Understanding your accessibility needs will steer you towards the right type of racking system that balances storage efficiency with ease of access.

Lastly, don’t forget about your warehouse layout and future growth plans. Consider the dimensions of your warehouse, including ceiling height and aisle width, to make sure you’re optimising space utilisation. And as your inventory grows over time, ensure that the racking system you choose can adapt to accommodate your evolving needs without requiring a complete overhaul. Taking all these factors into account will help you make an informed decision and select a pallet racking system that maximises efficiency and productivity in your warehouse or distribution centre.

The weight capacity of a pallet racking system is its ability to support and safely hold the weight of the goods stored on its shelves. Overlooking this crucial factor can lead to safety hazards, structural failures, and operational inefficiencies. It’s essential to accurately assess the weight of your stored goods and choose a pallet racking system that can handle the load.

The amount of weight that a pallet racking system can hold will vary depending on the type of system, and the manufacture and we will always advise to check the pallet racking you use is suitable for the good you store, especially if the goods have changed. Below we have given some guidance on the different pallet racking types and their weight capacities:

Adjustable pallet racking is the most common type of pallet racking, allowing direct access to each pallet. Weight capacities can vary but generally range from 500kgs to 2000 kgs per pallet position. Ensure to check manufacturer specifications for precise details

Ideal for high-density storage, double-deep racking systems have weight capacities similar to the adjustable pallet racking system, so range from 500kg to 2000kgs . However, it’s crucial to consider the accessibility constraints, as pallets are stored two-deep, making rear pallets less accessible. Also there is a weight reduction on rear pallets due to the truck operation.

Designed for high-density storage, drive-in systems can handle substantial weight. Capacities typically range from 500kgs to 2000kgs per pallet position. Consider the trade-off between storage density and selectivity.

With a Last-In-First-Out (LIFO) inventory management system, push back racking can handle weights ranging from 500kgs to 2000kgs per pallet position. It’s essential to consider the dynamic nature of this system when assessing weight capacities.

Commonly used for storing long and bulky items like pipes and timber, cantilever racking is generally designed around the goods stored and is therefore not as restricted on weight capacities as per the other options. The overall capacity depends on the length and thickness of the stored items.

When it comes to warehouse efficiency and safety, pallet racking often plays a central role. But as you evaluate your storage systems, you may wonder: Does pallet racking need to be certified?

The short answer: Yes, in most cases, it does. Certification ensures that your racking meets industry standards for safety, compliance, and performance, which protects your people, your inventory, and your business operations.

The Storage Equipment Manufacturers’ Association (SEMA) provides industry guidelines and codes of practice for the design, installation, and use of storage equipment, including pallet racking.

The Health and Safety at Work Act 1974 and the Provision and Use of Work Equipment Regulations 1998 (PUWER) impose a duty on employers to ensure the safety of their employees and the equipment they use. This includes pallet racking systems.

While SEMA certification is not a legal requirement, it is widely recognised as a mark of quality and compliance with safety standards.

Insurance companies may also require businesses to adhere to certain standards for pallet racking safety to maintain insurance coverage.