Industrial racking systems are the metal structures used to support goods in warehouses or industrial facilities. These systems are critical for smooth warehouse operations and play a central role in a company's logistics and supply chain management. Unlike floor storage, all racking systems offer the advantage of optimizing available warehouse space. With the growth of e-commerce and the need for extensive logistics and distribution networks nationwide, space optimization has become paramount. To meet this demand, businesses now have access to various pallet racking systems and picking solutions.
Over the years, the industrial storage systems sector has evolved from adjustable pallet racking to today's versatile, dynamic systems tailored to specific business needs. While there are multiple ways to classify warehouse racking systems, this article focuses on non-automated storage systems, dividing them into two main categories based on unit load types: pallet racking and picking solutions for cartons or small items.
While industrial racking may appear to be simple standardized products, they are actually the result of significant engineering research and innovation. These efforts have produced structures that optimize both space and time for global companies. Key elements for evaluating racking quality include:
- Engineering Design: Structural calculations, load and resistance studies, and seismic calculations by specialized technical teams are crucial for complex storage systems.
- Reliable Manufacturing: Automated production processes with quality control, traceability, and monitoring ensure high-quality racking at all stages.
- Premium Materials: Steel meeting the highest quality standards results in safer, more durable racking.
- Regulatory Compliance: Manufacturing and design must adhere to all global and local quality regulations.
- Testing and Simulation: All critical aspects must undergo field testing to verify element reliability.
Having established the hallmarks of quality racking systems, we now categorize non-automated industrial racking by their supported unit loads: pallet racking for heavy loads and picking solutions for light loads.
Pallet racking supports heavy loads handled by lifting equipment. These systems fall into four main categories: adjustable pallet racking, compact pallet racking, drive-in pallet racking, and mobile pallet racking.
Standard Adjustable Pallet Racking: These systems use forklifts to mechanically store pallets through parallel aisles, allowing direct and immediate access to all stored unit loads. They feature standard aisle widths and store single pallets at the rack's rear.
Narrow Aisle (VNA) Pallet Racking: A compact version of adjustable racking that creates higher-density storage without additional space. By narrowing aisles to a minimum width of 1.5 meters, VNA systems save over 40% space. Special VNA handling equipment is required for operation.
Double-Deep Pallet Racking: This traditional solution shares characteristics with compact racking by storing pallets two-deep for higher density. Unlike standard adjustable racking, operators cannot directly access all stored pallets, requiring forklifts with telescopic forks or pantograph mechanisms.
Compact racking maximizes space utilization by minimizing truck working aisles. These systems create parallel internal aisles for forklift access during loading/unloading. They're ideal when space optimization takes priority over direct access to all stored loads. The two main types are drive-in and drive-through systems.
Drive-In Pallet Racking (LIFO): The most common compact system requiring only one forklift entry aisle. It operates on Last-In-First-Out (LIFO) inventory management, making it suitable for homogeneous products with low turnover rates.
Drive-Through Pallet Racking (FIFO): This system requires two entry aisles (one on each side) and operates on First-In-First-Out (FIFO) principles. Recommended for high-turnover products, though with less space optimization than drive-in systems.
These systems use gravity and thrust to optimize pallet storage. The two main types are:
FIFO Gravity Pallet Racking: Features slightly inclined roller beds allowing easy pallet sliding. Pallets move from loading to unloading ends via the inclined roller system, making it ideal for warehouses requiring perfect inventory rotation.
LIFO Push-Back Racking: A gravity-based accumulation system using Last-In-First-Out management. Pallets are stored by pushing previous loads toward the rack's rear with controlled force. Two variants exist: shuttle-based and roller-based systems.
These systems feature metal structures mounted on mobile bases guided by floor-mounted rails. Only one working aisle remains open at a time, with electric motors enabling side-to-side movement. This makes mobile racking ideal for cold storage by reducing the volume requiring refrigeration.
Picking solutions (or long-span racking) store lighter, bulkier items like cartons or small products without requiring lifting equipment. Often used in order preparation, filing, or maintenance areas, these systems can combine with pallet racking for versatile warehouse solutions.
Allows manual storage of small-to-medium products with direct access to all materials. Highly adaptable to various unit loads, these systems easily incorporate attachments for specific industry needs.
Manual racking that optimizes vertical space through multiple accessible levels connected by stairs.
High-density storage for cartons and light unit loads using slightly inclined roller tracks for significant space savings and effective inventory control.
Similar to long-span racking but designed for lighter, smaller loads. Suitable for both industrial warehouses and offices, offering quick access to stored goods.