Pallet Racks

A pallet rack is an upright structure made of steel framing with beams and connectors that are bolted, welded, or clipped together to form a shelving unit to store inventory and equipment. In warehousing, pallet racks are...
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This article presents complete information for selecting a suitable warehouse racking system. Read further to learn more about.
Warehouse racking, also known as storage or pallet racking, is a material handling system suitable for mass storage of goods unitized on skids or pallets. It allows efficient utilization of space while providing easy access to stockpiled items for better inventory control. Racks are used by manufacturers for mass storage of mostly non-perishable products when storage space is not enough. Palletized products are usually stacked up to not more than three layers before it becomes unsafe and prone to collapse. A racking system enables manufacturers to store palletized products five to seven stacks high, depending on the height of the facility.
Aside from finished goods handling, racking systems are also used for raw material and parts storage. Selective racking can be designed so that the greatest number of items can be accessed, permitting high variety. Also, some distribution systems favor the use of FIFO or the first-in, first-out method of inventory control. Having a racking system provides access to the oldest items in the warehouse inventory, allowing them to be off-loaded first.
Aside from maximizing storage space, there are other benefits that make warehouse racking feasible. These benefits can be quantified in terms of economic value or savings from leasing additional storage space, less workforce effort, and higher throughput. On the other hand, compliance with safety standards and quality management are other value-adding factors that do not directly translate to savings. Enumerated below are the benefits of a warehouse racking system.
Palletization of materials offers an easy and convenient method for organization shipments and receiving supplies. A racking system is a way to place palletized materials in a safe and secure location such that they will not be damaged by mishandling, miscellaneous contact, or falling. Essentially, the metal frame of the racks keeps pallets from shifting and provides a protective barrier. The various designs of racking from two deep designs to excessively tall racking systems makes access to goods easy without disturbing surrounding pallets.
In a racking system, the location of an empty pallet can easily be found and accessed. This eliminates small unnecessary movements that, in time, stack up to significant losses.
Adapting a racking system is the first step to warehouse automation. This is achieved by integrating smart conveyor systems and guided forklifts and cranes. This can lead to significant savings in terms of manpower costs and can streamline the business process especially for large distribution centers.
Warehouse racking is designed to take advantage of storage space, arrange products efficiently, and provide a cataloging system making it easier to pick required items. Safety measures are a necessary part of the efficiency of a warehouse and are an integral part of racking system design. Included as safety measures are sensors and alarms, guard rails, rack end protectors, rack guards, and column guards.
By having better access, it is easy to clean goods and storage spaces. Better segregation can be achieved to separate goods that can possibly deteriorate or damage adjacent items.
Before investing in a racking system, it is important to note several factors to determine the viability of the project. Keep in mind that racks can also cause a space to be less utilized since the frame and its appurtenances take up space. The biggest drawback of a racking system is its difficulty in being modified and reconfigured. To make the most out of the investment, the following are some points to consider.
There are several racking designs and configurations suited for a particular application. Storage racks are generally divided into either high-selectivity, low-density or low-selectivity, high-density applications. Racking with high selectivity and low density are selective, double deep, and very narrow aisle racking systems. High-density applications are push-back, drive-in, and pallet flow. Special systems are also possible, which are basically modifications of the previous configurations.
Selective pallet racking has a high SKU count but offers the lowest storage density. Conventional selective pallet racking can be visualized as large shelves that have storage space for a single row of items. The racks can be arranged back-to-back to improve storage density, although they have low storage density because of the space consumed by the aisles. This type is mostly seen in raw materials warehouses, parts storage spaces, and distribution centers where there are many distinct types of products with low volume. Selective pallet racking can be combined with other types to accommodate SKUs with high volumes. Other properties of selective racking are its flexibility between FIFO and LIFO inventory management, the operability of standard forklifts, accessibility for cleaning and inventory accounting, and simple construction that allows for easy reconfiguration. Selective racking has different frame and beam connection designs that are divided into teardrop and slotted racks.
This is a modification of the standard selective racking where instead of using single pallet rows, two rows are used per pallet shelf. This increases the storage capacity of selective racking by 40-60%. This also preserves the advantages seen from the standard selective racking. To operate under FIFO inventory management, the adjacent rows must have the same SKU. This increases the storage density, but selectivity is lowered. The main disadvantage of using this system is the need for specialized forklifts or standard forklifts with double deep handling attachments. This leads to higher operating costs and requires well-trained operators.
The concept of this pallet racking is to further improve space utilization of a standard selective while maintaining 100% selectivity. This is done by loading pallets using a fork truck capable of side loading. This eliminates additional space intended for maneuvering the forklift. The aisle space can be minimized by up to 40%. A downside of this type is the need for two sets of equipment for loading and unloading. One is a side-loading fork truck, and the other is a standard forklift for moving products from the palletizing station to the staging area.
This type of racking involves loading the pallet on carts resting on a pair of rails that are available on each push-back lane. These carts are designed to be nested at the front of the aisle. To load a pallet, the forklift pushes against the other pallet, which moves it deeper into the lane. This dynamic racking system allows higher storage density than single or double deep racking. Each lane is one SKU that can be configured three to six pallets deep. Specialized forklifts with deep handling attachments are not needed since the pallet is readily accessible at the front of the lane. The lanes are inclined so that the carts roll towards the aisle. Each lane is a LIFO management since only the most recent pallet is accessible.
In this type, the pallets rest on a pair of rails that are specifically designed for the pallet dimensions to be loaded. The rails are designed to support the pallet while providing access to the forklift mast and fork as the forklift moves along the bay. Loading is done by driving a forklift into the last open position. Once in position, the pallet is slowly lowered into the rails. After loading, the mast is retracted, and the forklift backs out of the bay. Each bay is dedicated to a single SKU that can be several units deep, making it suitable for high-density storage but with low selectivity. This system is available in two configurations, drive-in and drive-through. In drive-in, the bay has only one access for entrance and exit, allowing for LIFO inventory management. The drive-through, on the other hand, has two access points, one for loading and the other for off-loading. This is used for FIFO inventory management.
This design employs roller beds that move the pallets into the last open position. The lane has two openings similar to a drive-through racking, one at the front and one at the rear. The pallet is loaded at the rear side. After loading, the pallet rolls along the lane towards the front side. This is achieved by having the lane inclined at the rear. Off-loading is done on the front side of the racks. Pallet flow, like drive-in and drive-through racking, is suitable for high volume, low SKU number applications. In terms of inventory management, this system is suitable for FIFO. It has the same storage density as a drive-through but not as much as drive-in racking since it uses two lanes. This dynamic system is better than drive-in and drive-through since it is not prone to damage from forklifts that can lead to collapse.
This type is ideal for storing long products such as roofing materials, pipes, tubes, and lumber. It is composed of upright columns with cantilever arms on one or both sides. Vertical clearances between the arms can be adjusted depending on the bulkiness of the product. The angles can also be adjusted to help with load retention. Unlike standard selective racking, cantilever racks do not have upright frames at the front that obstruct loading. Aside from storing long products, it can also store irregularly shaped items such as appliances and furniture.
The principle is similar to pallet flow racking. This type also has two access points, one for loading and the other for off-loading. Manual loading and off-loading can be done without the need for forklifts. This is ideal for high volume piece-pick applications such as in cold storages and food racks. Carton flow lanes can accommodate non-standard size items.
This type involves moving a whole rack assembly laterally to create an aisle space. Moving the rack is usually accomplished by driving it using electric motors. Smaller racks can also be mechanically or manually operated through pushing or pulling or by rotating handwheels with a high ratio. This type is a high-density storage system with high selectivity. However, access is not readily available as the racks need to be moved first for access. This is suitable for warehouses with low traffic.
As the name suggests, this type takes advantage of having high bays. They are most suitable for automated distribution centers for high density, high selectivity, and high throughput storage. The racks can be single, double, or in some instances, multi-deep rows. Automatic cranes with telescopic forks or order-picking trucks stabilized by rails and supports move along the aisle. The crane picks up a pallet from the conveyor system and places it on its designated rack. Due to the complexity and high cost of this system, it is only viable for warehousing that hedges profits on efficient storage.
Chrome wire shelving is highly versatile and inexpensive with the same strength as stainless steel. It has a clean finished look and can be used to store a wide assortment of items with a durability capable of holding trays, cartons, boxes, and storage containers.
Epoxy coated shelving, which can be gray, black, or green, is ideal for humid and wet environments. Some types of epoxy shelving can have an antimicrobial agent to prevent the buildup of bacteria, which is important for shelving used in the food industry and healthcare.
ASRS systems use software, computers, and robotics to make handling, storage, and picking smoother and more efficient. They can be adjusted and customized to fit any size warehousing system and are dependent on various technologies to automatically complete warehousing tasks.
There are several different types of ASRS systems that are capable of being configured to meet every type of warehousing need. The most common systems are:
Instead of using carts or roller beds, the system uses remotely controlled shuttles to lift and lower pallets and to move pallets. Since the length of a lane is not limited by the incline, shuttles have a large number of pallet positions per lane. This type can be utilized for FIFO and LIFO inventory management.
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