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Evaluation: Pallet Rack Storage Density, Access, Safety and Costs

April 24, 2025

High bay selective rack pallet storage.

Just how many pallets can you store in a 100′ x 100′ area? It can range from not that many–X with selective racks that let you pick or place any pallet at any time–or “Y” using incredibly dense, using pallet flow or drive-in systems that restrict how and when you can access pallets. The balance between storage density and selectivity is always critical, but there are other factors in play: cost, efficiency and safety.

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Double-Post Pallet Rack Systems: When, Why and How

January 7, 2025

Pallet rack system with two posts used for each rack bay

Most pallet rack systems are installed with a starter-adder design, which shares a common rack upright between consecutive storage bays. The alternative is a double-post rack system, where each bay has two independent uprights. Most of the time, starter-adder is used because it’s more economical and uses space more efficiently.

Given that it’s costlier and uses more space, why–and where–would you use a double-post design?

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Meeting the Demands of Cold Storage

September 17, 2024

pallet rack in cold storage facility

In the cold and frozen food sector, tremendous growth combined with a serious shortage of capacity is severely constraining companies today. “The frozen food market is currently experiencing remarkable growth, with its global value soaring to $265 billion. In the U.S. alone, new frozen food sales have impressively surpassed the $72 billion mark,” states Rick Kingery in the Colliers’ article “Capitalizing on the $265 Billion Frozen Food Market: Cold Storage’s Crucial Role.”

Adding to the challenge, “We estimate the U.S. will need up to 100-million-square-feet of additional cold storage space in the coming years,” states Marty Khait in an article posted on the Refrigerated & Frozen Foods Magazine website, “The Cold Reality: Why America’s Cold Storage Capacity is Running Low.”

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Pallet Flow Maintenance – What Matters?

August 27, 2024

pallet flow system in facility

Your pallet flow system produces a smooth, orderly process first-in, first out product flow. To ensure it performs, regular inspections and timely repairs are essential. Although pallet flow systems typically require minimal maintenance, proper employee training and consistent checks can help avoid misuse and prolong the life of your equipment. Pallet flow systems are built to flow heavy pallets from infeed to picking, using brakes and dampeners. Over time, these components must be inspected, maintained or even replaced for optimum, safe performance.

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It’s Critical: Pallet Rack Load and Application Drawings

June 18, 2024

 

warehouse pallet racking

It’s a fact of life: companies need to adapt to new business, and that means the warehouse.

Your customer base might change. Your company’s inventory strategy could differ from year to year, which means new loads and shifting layouts. You may need to move racks from one place to another or supplement them with new components or replace damaged ones. To be sure your warehouse is safe, you should have load and application drawings.

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10 Easy Tips to Increase Warehouse Safety

February 15, 2024

forklift accessing load stored on pallet rack

Insufficient safety measures in warehouse and distribution centers can have severe repercussions, including injuries, operational downtime, product losses, property damages, and potential legal actions. Of particular concern are accidents involving collisions between forklifts or other vehicles and employees or visitors.

Within busy operations, a forklift or other vehicle may eventually run into existing rack. While the rack may not require immediate replacement, storage capacity and product throughput may be compromised for some time. If overloaded, or loaded incorrectly, a rack can also collapse, spilling the inventory to the ground. Employees and visitors must also be protected from vehicle traffic.

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How to Specify Dock Area Pallet Racks

January 9, 2024

Busy warehouse shipping dock with pallets stored in racks and on the floor

Above: pallet racks are installed both to the side and in front of dock doors in tight space. Palletized loads are floor-staged nearby, further squeezing space.

Warehouse shipping docks are one of the busiest areas in any warehouse. You have the buzz of constant activity as shipments are received or processed out the door, with a mixture of people on foot, forklifts, carts, floor scales, pallets and storage areas. There may be extendable conveyors or other equipment in the same relatively compact footprint. During busy times, it gets more congested and less workable.

It’s also a popular area for palletized storage on, near and around the area. Here’s what to keep in mind:

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Pallet Rack: Anchoring, Safety and OSHA Compliance Factors

November 9, 2023

heavy duty die storage rack anchored to a concrete warehouse floor.

Warehouses use pallet racks because they maximize storage space, streamline operations, and organize inventory like no other system. We discuss rack safety in depth because it’s so critical for protecting people, property, inventory and facilities. A rack safety fundamental is anchoring: the right anchors, installed correctly, into a subfloor designed for that purpose. Think of the floor-rack connection as the very basis of your rack’s balance and capacity.

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Damaged Pallet Rack: Repair or Replace?

May 11, 2023

Warehouse managers surveying racks for damage and procedure.

Whether you replace or repair pallet rack, it’s always advisable to evaluate the structural integrity and safety of damaged rack components. When you’re considering a repair strategy, you should be aware of the strength and limitations of your options.

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Options for Pallet Rack Floor-Level Storage Versatility

May 2, 2023

Warehouse

Change is inevitable, particularly in warehousing, manufacturing and distribution. Many warehouses will shift storage area missions over time. New SKUs, more inventory, and different business and operational missions can create the need for newer storage concepts. The problem? There isn’t always a place for new demands. When this occurs, one thing to consider is using the floor or lower levels of your rack system.

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