Eight Pallet Racking Configurations Explained

Group Article – April - Eight Pallet Racking Configurations Explained
Eight Pallet Racking Configurations Explained
Pallet racking has been the most popular form of storage for decades. Ever since the first retailer started running out of space, this simple and effective form of shelving has provided the backbone to every successful business. It’s still the number one choice for storage for manufacturers, wholesalers, retailers, logistics companies and even museums and other repositories all over the world.
Whilst the principle behind pallet racking hasn’t changed much over the years, what has changed are the range and type of products that need to be stored, and more importantly accessed, swiftly and safely for onward delivery to its final destination. All these changes have resulted in the development of different types of pallet racking systems, and the means of accessing them.
With so many variations and options to choose from - and many permutations that can be combined or installed together -do you find the one that is right for you?
The best place to start is by drawing up a checklist of the key storage issues that you face in your operation. The most frequently mentioned include:
•    Insufficient capacity
•    Inability to adapt to meet changing needs and stock
•    Wasted space above racking
•    Inefficient and slow picking operation
•    Wasted aisle space
•    Need to reduce staffing levels
•    Over-reliance on specialist forklift trucks
All pallet racking will address these issues to a greater or lesser extent, so it’s now down to deciding which type offers you the solution based on your priorities.
Let’s have a look at what options are available and what each can do:
1. Standard Wide Aisle Pallet Racking
While accommodating pallets on rack heights of up to 30 metres with maximum bay loads of more than 30 tons, this system provides high stability and unrestricted access at all times.
The system delivers versatility and assembly as single or double-depth racks. Extra features and a wide range of accessories are also available.
2. Narrow Aisle Racking
This can be a great solution when the storage floor space is limited. It allows quick order picking and fast access to any section of the system.
With a height that can go up to 12m and configurations that increase storage efficiency due to high density, the narrow aisle pallet racking may prove to be a good value for your investment.
3. Mobile Pallet Racking
Mobile Racking (MOVO) can be the ideal solution if you are looking to save space and increase storage capacity. Offering technical superiority and total flexibility, it is suitable for all kinds of stored goods.
Among the amazing benefits of this system, we should mention the reduction in energy, operating and cleaning costs, a good return on investment (ROI), full access to individual pallets and a wide range of accessories.
4. Pallet Shuttle System
A semi-automated, high-density storage solution that works in either First in, First out (FIFO) or as Last in, First out (LIFO). Ideal for situations such as cold storage, food and beverage production, and meat processing. It is cost-effective, time-saving and removes the need for forklift trucks to enter the aisles.
This system offers a very effective high-density storage with a low level of risk or damage to the equipment or operating staff.
5. Drive-in Pallet Racking
Creates efficiencies by reducing aisle loading and unloading times, yet allowing greater access compared to block-stacking. It can free- up as much as 90% of existing floor space, compared to conventional systems.
Since it allows a limited stock rotation and it is only accessible by the FILO (First In, Last Out) principle, Drive-In pallet Racking can be a good solution for storing seasonal goods or chilled products.
6. Cart Push-back Trolleys
Offers high-density live storage to provide quick and easy access to loads from the same aisle face. This reduces truck travel distances and cuts cycle times. Can also be used to provide additional storage space in otherwise unusable areas, such as above cross-aisles or around dock-levellers.
This system is ideal to maximise floor space and it is accessible by LIFO (Last In, First Out) principle. It can store up to 6 pallets in depth with up to 1400kg per pallet space.
7. Pull-Out Units
An efficient system that moves pallets back and forth like drawers, even with a full load up to 1000kg. Its ergonomic design reduces operation distances to allow faster and more efficient picking saving both time and space.
By installing pull-out units in your pallet racking, the number of pallet and picking locations can be increased, while still taking up the same space as before.
8. Push Back Rollers
A dynamic storage solution ideal for storing bulk goods on pallets that can be used to provide additional storage space in areas that may not be suitable for other systems. Up to 75% increase in storage capacity compared to conventional storage.
It rolls pallets automatically to the pick-face. The maximum storage capacity is 9 pallets per bay, accessible by LIFO (Last In, First Out) principle.
In short:
•    Handling mixed articles: Standard Aisle, Narrow Aisle, Mobile, Push-Back.
•    Adaptability: Standard Aisle, Narrow Aisle, Mobile.
•    High Density storage: Drive-in, Pallet Shuttle, Pallet Flow, Mobile.
•    Life-time costs of the system
•    Good for FIFO: Standard Aisle, Narrow Aisle, Pallet Shuttle, Pallet Flow, Mobile.
Need more information?
If you need any help or advice on design or a technical issue, Dexion is a good place to start. As one of the pioneers in developing pallet racking, we provide analysis, advice and ongoing support. Contact us at

Profitable Warehouse Expansion
Like all good partnerships, any warehouse expansion requires careful co-ordination between two industry partners; customer and materials handling manufacturer to ensure Return on Investment (RoI).
It begins with good planning. To start with, it would be wise to forecast, perhaps up to as far as ten years ahead, projecting your growth and aspirations. Whether the premises is owned or leased, now would be a good time for management to review current and proposed metrics such as SKUs, pick rates and orders processed. Consider the types of goods you handle - are they fast moving or C-Type slow movers?
If the current operation is largely manual, are you going to consider automation? If so, when is the ambition to become largely automated?
If you’re considering expansion, it’s likely that your inventory will be bigger. You’ll know whether your old way of doing things is unlikely to work anymore if you fail to replenish as quickly and accurately as you know you should be. In that case, now might be the time to consider automating these processes to avoid future errors. Your receiving area will invariably be bigger and taking in more stock. In order to avoid a slowdown, you’ll probably want to receive, verify and sort your products as quickly as possible. Again, introducing some automation now or in the future could be a good solution. To achieve this, you may well need to adjust or even ditch your previous receiving processes. In any case, any planned investment should be carefully considered and be financially justifiable.
Think about creating a good working environment for your staff. Solely concentrating on stock placement alone can sideline considerations like having the right lighting and establishing picking routes that make their jobs easier and more importantly, safer.
So, who will you partner with to achieve all of this? Pick a well-established storage industry manufacturer who can provide a solid record of success, a portfolio of compatible product solutions and a cradle-to-grave sustainable, safe service solution; a partner who can developed future proofed products which can dovetail neatly into your expansion programme as it progresses.
Dexion Analysis & Advice
So where does the specification start? Dexion doesn't just offer general advice and guidance about your storage requirements; we go further to provide you with practical assistance and advice with a more detailed analysis of your storage requirements.
So where does the specification start? Dexion Our own in-house analysis will translate your storage needs into a specification report, evaluating all areas of your warehouse, including:
•    The layout & storage equipment you require
•    Your material storage locations
•    The optimal material handling processes & picking speeds
•    Life-time costs of the system
•    Growth strategies and market trends.
We determine your optimum layout, system and process flow to ensure your warehouse is continually optimised.
Dexion products are designed to withstand tough environments. And they don’t get much tougher than warehouses and distribution centres.  The constant movement of goods, forklift trucks and pallets takes its toll on any storage system. We can also supply you with several accessories to keep both your storage system and employees safe.
Once a specification is produced, the design and installation process is undertaken by qualified engineers and trained installers. A full follow up service regime can be provided to include rack inspection, heath & safety, service and maintenance, together with courses and seminars.
Case study: UK soft drinks manufacturer enhances distribution service within existing warehouse footprint
A manufacturer of soft drinks was seeking to increase production and sought to streamline its 150,000 sq. ft distribution without adding to the warehouse footprint. The well-known brand produces soft beverages and sales are summer weather dependent. Batches need to be fully traceable; storage is a continuous process and distribution by lorry operates 24/7. The challenge was to increase throughput by offering an enhanced fulfilment-oriented service to an FMCG client base.
Working closely with our customer over a period of 3 years, we designed and installed a 15,000 pallet storage shuttle system to modernise the efficiency of the existing warehouse operation from receipt of product through to output.
The system, designed initially in semi- automated mode, was designed to accommodate up to 300 pallet movements per hour – an increase of 200% on their existing storage system. This provided the required level of growth to the business; with the initial concept designed for automation at a later stage to realise further benefits against ambitious growth targets. The business was able to ‘grow’ into this additional capacity, by adding additional shuttles later – offering strong ROI on the initial investment.
Within three years, the business had exceeded all growth expectations and had reached the pallet movement ceiling for the ‘manual’ operation. This resulted in the second phase of the system being installed, which incorporated the automation of the system; increasing the system to 600 pallet movements per hour and maintaining their ongoing growth plans.
Read the full case study here
About us
With a group turnover of almost 200 million Euros in 2018, Dexion is part of Gonvarri Material Handling, a leading pan-European provider of storage products and solutions. In addition, the Group is marketed throughout Europe under the Constructor, Kasten and PSS brands.
Products range from innovative pallet racking and shelving technology to office and archive storage solutions. We provide a complete package of services including consultancy, planning and maintenance whether the requirement is for the fitting out of a warehouse or distribution centre or a shelving solutions for retail, manufacturing and automotive industries.
To contact us or to find out more, please visit

Investing in Pallet Racking 10 Tips
Thinking of buying pallet racking? Ten things to consider before investing
Whenever a business makes an investment decision it is vital to consider the options, and this is equally true of investing in pallet racking for your warehouse.
Indeed, if you invest in the wrong type of pallet racking for your business, it could have a detrimental effect, by slowing down or hampering the smooth-running of your warehouse.
Getting the storage solution right and investing in the correct pallet racking can make the difference between a seamless and efficient warehouse operation and one that works against your business workflow. Experts in warehouse storage solutions can assess which pallet racking best suits each environment.
Here are ten key things to consider before you take that all-important step and invest in pallet racking.
What is your budget?
This should be the first step with any business decision. It is essential to allocate sufficient funds to your pallet racking investment. You should also bear in mind that the cheapest is not necessarily the best option. Low cost racking may not be versatile and adaptable enough to expand and change, as your operational needs changes. You may soon find yourself having to start again with a new solution, so losing your original saving
What does the racking need to do?
There are many different types of pallet racking, to serve multiple functions. Therefore, it is essential to first define your purpose and pick a solution that meets your needs. What do you want your racking to do? What type of goods will be stored? How often will you need to access the goods? All this information needs to be gathered and collated before any solution is proposed.
What is the floor plan and layout of your warehouse?
Warehouses come in many shapes and sizes, with varying footprint. It is important to map the area, with accurate dimensions, as well as access points, doors and windows clearly marked.
At this stage, it is advisable to call on the services of a warehouse solution specialist, as they will be able to assess not only the best type of racking to use, but how best to fit the warehouse to maximise workflow and functionality.
How high is your warehouse?
Don’t restrict yourself to looking at the floorplan, but taking into account the vertical space.
Warehouse solution specialists always think and work in 3D – that is, they look at both the floor plan and the height, and they then devise a racking system which makes the best use of all the space available
In some cases, by making full use of the height of a warehouse – even up to 40metres – you could double your storage capacity. However, do factor in other associated costs, such as a warehouse crane and lifting equipment.
What access do you need?
If you store goods that need to be accessed frequently, you must factor this in when selecting your pallet racking solution. If you need occasional access you may find a different solution suits you better than if you need frequent access.
It is not uncommon, in our experience, to come across businesses which struggle with their storage because they fail to take account of how frequently they need to access the stock.
Think about safety
In any working environment health and safety is an important consideration, and none more so than in warehousing. Warehouses can be busy and potentially dangerous places, with people, vehicles and large goods and items all being moved around simultaneously.
It is important to ensure not only that the pallet racking you choose is of a high standard but that it is correctly installed. Thereafter, ensure annual safety checks on your pallet racking are carried out, so safety standards are maintained.
Look to the future
When selecting pallet racking don’t focus only on your needs of today but look at your future needs and your planned business development. If your business is likely to change, then you will want to invest in warehouse storage that has the versatility to grow and change alongside. You might want to consider versatile racking, which can accommodate different sizes of product and cater for different uses.
Without this foresight, you could find yourself investing in one type of pallet racking, only to find you need to change it again in a few years’ time. Versatility and adjustability are key.
What storage do you already have?
We have talked so far about new pallet racking but it is just as important to consider what you already have in terms of storage. You may have storage that is fit for purpose, and be able to invest in extra storage to complement it.
Look, too, at what else is in your warehouse. What vehicles, such as forklifts, do you own or plan to buy? Any racking must be able to accommodate these.
You may also need to change or adjust your lighting so that it works harmoniously with your new storage.
How hard-wearing should your racking be?
Different warehouses have different requirements and so need different storage solutions in terms of durability. If your racking needs to withstand extremes of climate– such as sub-zero temperatures – it needs to be robust enough to cope.
And how long-lasting does the storage need to be? Are you planning on keeping it for years or is its purpose more short-term? Does the racking need to be scalable or fixed? Your answers will dictate your choice of pallet racking.
Looking after your storage
Once installed, you will need to be able to maintain your storage. This means, it is advisable to select storage where spare parts are readily available, and where there are experts e to call on to carry out any necessary maintenance or repairs. In other words, whoever provides your storage needs to be able to offer excellent ongoing support and maintenance. Otherwise, again, you could end up with a poor investment.
We hope this has answered some questions about what to consider before investing in pallet racking. If you would like more information and to talk to our expert team please get in touch with us today.