WOI Risk & Reward Series – Drive-In Pallet Racking

Get to Know Your System Before You Dive Into Drive-In Pallet Racking

Drive-in pallet racking systems provide dense storage for palletized inventory. By comparison, a drive-in system would save between 35% to 80% of the space required by a selective rack system for the same pallet capacity. With that being the case, it would seem that drive-in rack would take over the warehousing world; however, as beneficial as a drive-in system can be, design considerations don’t always satisfy inventory and operational needs. Taking a good, objective view of pallet racking system options is best to make an informed, practical choice.

Drive-In Pallet Racking Scenic Overview

Clearly, what sets drive-in apart is its consolidated footprint. High pallet capacity is achieved through the unique design of multi-levels of deep lane storage. Drive-in systems do not require cross beams used in most pallet rack systems. Instead, each storage level within the drive-in lane is equipped with rails that protrude from the left and right sides. The forklift operator drives into the lane to the farthest empty pallet position to place the pallet on the rails and then slowly backs out of the lane.

Drive-In Rewards

• High-volume pallet storage
• Save 35% – 80% warehouse space
• Dedicated SKU lanes improve speed and accuracy
• Leverages vertical cube space
• Condensed footprint saves utility expense

Drive-in is a Last-in/First-Out (LIFO) inventory rotation storage solution as typically designed; however, you can configure it with forklift access from the opposite aisle for pallet extraction creating a First-in/First-out (FIFO) system. FIFO systems are popular in cold storage operations due to inventory date sensitivity. 

There are a lot of positives to a drive-in pallet racking system, but it’s essential to be aware of the challenges the system can pose, as well as the options available to mitigate those risks.

Drive-In Risks

• Forklift interface increases accident potential
• Pallet size must be consistent
• Honeycombing potential if SKUs increase & volume/SKU decreases

Forklift interface – the most significant “risk” with a drive-in rack system is that forklifts drive into the rack system to place the pallets on the side rails. It takes well-trained, skilled operators to do this effectively. 

Column guarding – guarding products can protect the vulnerable lower portion of the pallet rack system column. Additionally, many system designs feature a recessed frame design that angles the lower front column back and away from the aisle. The recessed frame design expands the turning radius for the forklift to remove the potential for forklift strikes.

Pallet specs – drive-in systems are carefully designed to fit the pallet specs. The pallet must balance squarely on the side rails. Too small of a pallet will drop; too large will not fit. It is also important to note that drive-in systems are restricted to counterbalance forklift access. The forklift must have proper clearance under the rails and between the columns. Outrigger-equipped vehicles and larger stacker or straddle vehicles will be too large to enter the lane safely.

Ultimately, it comes down to the number of SKUs, SKU volume, and turn rates as to whether Drive-in is a good option to explore for your operation. The design details then become crucial to execute a safe and effective storage solution. That’s where the WOI team comes in.  

Expert Design & Installation Drives Safe Operations 

Warehouse Optimizers, Inc. (WOI) is a trusted, full-service supplier of warehouse solutions with decades of experience helping customers improve operational efficiency. Our team understands how critical it is for your intake, storage, order processing, and staging solutions to work seamlessly together. Working closely with you, we will find the path to get you to your goals.

WOI is dedicated to complete customer satisfaction in all our projects. We abide by our 5-Step Total Satisfaction Experience™.

WOI will:

1. Listen to your needs
2. Execute your project with special attention to your unique application
3. Stick to project timelines
4. Ensure a safe environment
5. Pay close attention to the detail  of the finished product

Call Storage Solutions today to discuss your storage and processing needs. Let us help you find the most productive and cost-effective resolution. Call (865) 540-4004 for a prompt response. We proudly serve customers throughout the Southeast, including KENTUCKY, TENNESSEE, NORTH CAROLINA, ALABAMA, AND FLORIDA.