Drive-In Pallet Rack Takes High-Density Storage to a New Level

Drive-In Rack — Expand or Extend to Increase Capacity?

Drive-in pallet rack is one of the most high-density pallet rack storage systems. It features a super compact design that optimizes vertical cube space to provide high-capacity storage while requiring only a single aisle for access. With the unique design, forklift operators drive into the system to place pallets, hence the name.

As opposed to supporting pallets on front and rear beams like standard pallet racking, drive-in rack relies on rails that run the depth of the lane and extend slightly into the bay to support the pallet. Forklift operators drive into the lane to deposit pallets starting from the rear of the lane, loading from the floor up and from back to front, supporting a last-in/first-out (LIFO) inventory rotation.  

The compact, LIFO design is ideal for large volume SKUs with a high turnover rate –a low number of SKUs is optimal. Pallets are loaded back to front which works with common SKUs well. Drive-in rack can accommodate up to 75% more pallet storage than typical selective racking due to high-density storage with minimal forklift aisles. 

Drive-In Pallet Rack Benefits

• High-density pallet storage
• Optimize cube space
• LIFO stock rotation
• Dedicated SKU lanes
• Standard forklift
• Minimal forklift aisles

How to Add Pallet Positions Without Expanding Your Footprint

The deep lane, multi-level drive-in design can store a significant number of pallet positions in a comparatively small amount of floor space. However, what if you need to increase your capacity? Do you use up more of that floor space, or… can you expand the height of an existing system? This is a question that the Warehouse Optimizers, Inc. (WOI) team recently addressed for a customer, and the answer may surprise you. Take a look.

The existing rack system stores raw materials for an alcohol distillery. Like any busy manufacturing or distribution operation, external forces such as supply chain pressures, demand fluctuations, and rising material costs can affect how much stock you hold. Once adequate quantities may now be insufficient, harder to get, or more costly, leading our customers to consider increasing their holding inventory. However, with the current rack system maxed out, we were left to consider the most effective alternative.

Upon evaluation, the ceiling height of the facility is high enough to allow for the rack system to be safely extended by another pallet level. Custom-fit 42” pallet rack extensions can be ordered and installed onto the existing drive-in rack system. With rack extensions, the customer can double stack the level 2 & 3 pallet positions creating 324 new pallet positions without expanding the rack footprint. That’s a 20% increase in capacity without reconfiguring any equipment or operations in the area around the rack system. That’s a win-win for the WOI warehouse optimizer team.

Safety & Efficiency in a Full-Service Package

When you face a warehousing challenge, you want to work with a provider that can take you from idea generation to completed installation. The WOI team is that provider. Our staff has over 100 years of combined material handling experience. We offer full-service warehouse optimization and systems design with access to a broad network of top-quality suppliers & products. Our installation crews are full-time, on-staff professionals that adhere to strict conduct and safety rules.

WOI Professional Warehouse Installation Teams

• OSHA Trained & Certified
• Certified Drug-Free Workplace
• Licensed General Contractor
• Job Safety Analysis
• Forklift, Scissor Lift, and Aerial Lift Operator Trained

Call WOI today for a free consultation and no-obligation site inspection. Ask about our 5-Step Total Satisfaction Experience™ that strives for 100% Customer Satisfaction for every project.

Dial (865) 540-4004 or email info@warehouseoptimizers.com for prompt service. We proudly serve customers throughout the Southeast, including KENTUCKY, TENNESSEE, NORTH CAROLINA, ALABAMA, AND FLORIDA.