Pallet racking is a system used to organize goods on pallets or similar supports, making them easier to store and transport throughout the supply chain. Developed during the Second World War to enhance transport efficiency, it was originally made from wood. Today, pallet racking is primarily designed to store heavy palletized loads in warehouses and logistics centers, offering an efficient and organized storage solution compatible with industrial handling equipment.
Key Benefits of Pallet Racking
Palletising goods for industrial storage provides several operational advantages. It enhances efficiency, organization, and safety in warehouse operations.
- Streamlined loading and unloading times
- Efficient use of warehouse space through compacting goods
- Improved safety during transport and storage
- Greater flexibility in handling and transportation
- Better stock and inventory management
- Reduced handling, transportation, and storage costs
Choosing Between Selective and Compact Pallet Storage Systems
When selecting a pallet racking system, it’s essential to consider warehouse space, accessibility, and turnover rate. There are two main categories of racking: selective storage systems (providing direct access to every pallet) and compact systems (maximizing storage density).
Companies must assess their operational priorities — whether maximizing available space or ensuring fast and easy access to goods. Factors such as product type, stock rotation frequency, and inventory management needs play a critical role in the selection process.
Types of Pallet Racking Systems
Different pallet racking systems are designed to suit various warehouse layouts, storage needs, and inventory turnover rates. Below are the most common types:
- Adjustable Pallet Racking: The most common and simple type, offering direct access to all pallets with forklifts. It requires more floor space but provides flexibility and easy access.
- Very Narrow Aisle (VNA) Racking: Optimizes warehouse space by reducing aisle width, increasing storage density while maintaining direct access to all pallets. Requires special narrow aisle forklifts.
- Double Deep Racking: Increases capacity by storing pallets two-deep. It boosts space efficiency but reduces direct access to every pallet.
- Drive-In & Drive-Through Racking: High-density systems where forklifts enter the racks for loading and unloading. Drive-In follows LIFO (Last-In-First-Out), while Drive-Through uses FIFO (First-In-First-Out).
- Live Storage (FIFO): Uses rollers set at a slight angle to allow pallets to move forward automatically. Ideal for stock rotation and perishable goods.
- Push-Back Racking: Operates on the LIFO principle. Pallets are loaded by pushing back the previous ones on rollers or carts, maximizing storage density.
- Mobile Pallet Racking: Mounted on motorized bases guided by floor rails, allowing racks to move laterally and open a single working aisle when needed. Highly space-efficient and perfect for cold storage.
Understanding the Cost of Pallet Racking Systems
One of the most frequent questions from clients is how to calculate the cost of a pallet racking system. There’s no single fixed price since multiple variables influence total cost, such as design, material, load capacity, and market conditions. At Zawaya, we prioritize transparency and accuracy by providing realistic pricing based on your exact storage requirements.
Key Factors Affecting Racking Cost
Pallet racking costs depend on structural requirements and environmental conditions. While some elements like height and weight capacity are predictable, others—like raw material prices—can vary significantly.
- Weight Capacity: Heavier loads require stronger, often more expensive materials like structural steel.
- System Height & Configuration: Taller systems need reinforced frames and engineering compliance.
- Material Type: Steel quality, coatings, and finishes impact durability and price.
- Market Conditions: Global steel prices and logistics costs affect overall pricing.
- Safety & Compliance: Load Application and Rack Configuration (LARC) drawings and local building codes can add engineering costs.
To determine accurate pricing, consultation with a racking supplier is essential. They can evaluate storage needs, design specifications, and safety standards to offer the best solution within your budget.
