PALLET RACKING FAQ’S
We’ve gathered together the most frequently asked questions about pallet racking.
Choosing the right type and configuration of pallet racking for a business can be complex. To simplify this process, we have addressed the most common questions about these storage solutions, enabling you to make a more informed decision tailored to your needs.
Pallet racking is a system of beams and uprights used to support pallets in a warehouse. There are numerous version of pallet racking. The most common is adjustable racking (APR), others include drive-in racking, push back racking, pallet mobile racking, pallet live storage racking and narrow aisle racking.
The pallet racking market in the UK used to be dominated by UK manufacturers. For many years Dexion speedlock pallet racking was the dominant product closely followed by Link 51 pallet racking.
The largest pallet racking manufacturer in the UK is now Link 51. Link 51 pallet racking is manufactured in Telford by Whittan Storage Products Ltd and can be bought direct or through distributors. Surprisingly the racking can be bought at a lower cost from a distributor through the Moresecure side of the business. Whittan should be commended for maintaining faith and continue to manufacture in the UK where the costs involved are much higher and hence Link 51 racking is often not competitive. More and more pallet racking suppliers are manufacturing or sourcing the products from overseas. For example HiLo and Planned Storage (PSS) have merged and now manufacture a great deal of their products in Romania.
The other main UK pallet racking manufacturers are Redirack and Linpac formally known as Apex racking. Redirack is probably unique in that they have a welded racking frame (in other words the author cannot think of another manufacturer still offering a welded frame in the UK) which is best welded frames or bolted racking frames has been a long disputed. However, even the USA which for years have championed the welded frame are now switching to the bolted racking system. The USA market leader has just switched from welded to bolted. One thing for certain it is a lot more expensive to repair a welded frame that a bolted one. Redirack in respond to this problem have developed a sacrificial leg.
Linpac’s system like Rediracks is a well established tried and trusted pallet racking system. It does however have the advantage of a bolted frame.
Probably the country making the most racking in Europe is Italy. For years they have combined a low cost manufacturing base with high levels of engineering. One of the leading Italian manufacturers is Torri Racking. Unlike most of the UK systems that have a beam adjustability of 75mm Torri’s is 50mm. This has an added benefit of allowing a 5 tongue pallet racking beam connector whereas the norm is 3. However Torri double up the connectors and the beam is in contact with the upright by 10 connecters at each end. Click here to learn more about Torri racking.
Pallet racking systems are available in various configurations to accommodate different storage requirements and spatial limitations. The most widely used types are:
- Adjustable pallet racking systems. These versatile systems are the backbone of many warehouses. Adjustable racks feature parallel rows of upright frames with adjustable beams, allowing easy access to each pallet from a dedicated aisle. This design facilitates efficient product rotation, making selective racks ideal for warehouses with frequent pallet movements and retrieval operations.
- Drive-in and drive-through racking systems. Drive-in and drive-through racking systems allow businesses to maximize vertical space and achieve high-density storage. These systems eliminate the need for multiple aisles by allowing forklifts to enter the rack structure.
In a drive-in system, forklifts can access pallets from one side, while drive-through racks enable access from both ends, streamlining material handling and increasing operational efficiency. - Push-back racking systems. Push-back racking systems are designed with a “last-in, first-out” principle and offer high-density storage and easy accessibility. When a new pallet is loaded from the front, it pushes the existing pallets back, creating a compact and organized storage solution.
Consider your inventory type, space availability, forklift access, and rotation needs (FIFO or LIFO). Consulting with a storage specialist can help determine the best fit.
Selecting the appropriate pallet racking system is crucial for optimising your warehouse operations. Consider the following:
- Warehouse layout and size. Evaluate your available floor space, ceiling height, and aisle dimensions. These factors will be crucial in determining the most suitable racking system.For example, smaller warehouses with limited floor space might benefit from high-density solutions like drive-in or push-back racks. In contrast, larger facilities with more aisle space might prefer selective racking systems.
- Product characteristics. Heavy or irregularly shaped items may require specialized racking solutions like cantilever racking to accommodate their unique characteristics. These solutions ensure safe and efficient storage while preventing damage or instability.
- Material handling equipment. Ensure compatibility between your racking system and the forklifts or other material-handling equipment used in your warehouse.
Factors such as aisle width, lift height, and maneuverability should be considered to facilitate smooth operations and prevent potential accidents or bottlenecks. - Growth projections. As your business grows, so will your storage requirements. Choose a scalable pallet racking system that can adjust to your future growth and evolving inventory needs.Opt for modular systems that offer easy reconfiguration or expansion. This flexibility will help you keep pace with changing demands and stay ahead of the curve.
Industry standards and regulations govern the design, installation, and maintenance of pallet racking systems to ensure safety and compliance. When considering the safety regulations for pallet racking, it’s important to keep in mind several key guidelines and standards to ensure both compliance and safety in the warehouse environment
One key advantage of pallet racking systems is their modular design, which allows for relatively easy installation and dismantling. Most modern pallet racks are designed with a boltless or clip-together construction, eliminating the need for extensive welding or permanent fasteners. This modular approach offers several benefits, such as:
- Flexibility. Pallet racks can be reconfigured, expanded, or downsized as your storage needs evolve without major renovations or demolition. This flexibility allows you to adapt your storage solution to accommodate new product lines, changing inventory levels, or shifts in operational requirements.
- Portability. If you need to relocate or restructure your warehouse, pallet racks can be dismantled and reassembled in the new location. This portability minimizes disruptions to your operations and reduces the need for costly replacements or new installations.
- Cost-effectiveness. The ability to reuse and reconfigure existing pallet racks reduces the need for frequent replacements, saving you money in the long run. The modular nature of these systems also often requires less labor and installation time, further contributing to cost savings.
