Conventional Pallet Rack vs. High-Density, Space-Saving FIFO Pallet Flow

Which Storage Solution is Best for Your Warehouse?

As long as your warehouse has four walls, you have limited useable space. Since you are paying for the full floor-to-ceiling and wall-to-wall area, optimizing that space becomes a critical economic and operational goal. Pallet racking is nearly ubiquitous in warehouses and distribution centers because it maximizes vertical space and opens up floor space to help meet that goal. However, there is more than one style of pallet racking, so how do you choose the rack system (or systems) that will meet your facility’s precise needs?

A good place to start when evaluating rack systems is by completing an analysis of your inventory (number of SKUs and SKU volumes), turn rates across the product lines, seasonality concerns, and of course, space availability. It is also essential to consider your inventory flow from dock intake through order processing. 

Armed with a thorough operation overview, you can consider your storage racking options. Selective pallet racking is the most common warehouse rack because it’s typically the lowest cost and least complicated to build and use. However, it requires more space than a high-density system that can also offer productivity benefits. Let’s take a look at selective vs. a popular high-density system, pallet flow rack, as a good comparison between static, simple racking and dynamic, high-density pallet storage.

Roller Pallet Flow Rack

What is Pallet Flow Rack?

Pallet flow rack is one of the most flexible warehouse storage solutions for palletized or crated inventory. It is easy to use, low maintenance, fully customizable, and efficient. It is best suited for an inventory mix of a limited number of high-volume SKUs. 

The system comprises multiple levels of individual SKU lanes fitted with rollers or wheeled rails set on a downward pitch. Pallets are loaded from a rear aisle and then flow to the opposite aisle for extraction. The separate aisles allow for less forklift congestion at the rack and concurrent load and pick activity. Pallet flow lanes average between 2 – 6 pallets deep, but the system can allow for lane depths of 20+ pallets, making it a contender for very high-density storage needs. 

Besides multi-level pallet flow designs, the roller or wheeled rails can also be floor-mounted. Floor-mounted pallet flow is ideal for case picking from palletized stock –usually reserved for high-volume, medium-turn rate SKUs. Floor-mounted pallet flow is also ideal for minimizing forklift travel for pallet intake, dock staging, and supercharging high-volume layer picking. 

Wheeled Pallet Flow Rack

Designing your pallet flow system will depend on your pallet and inventory specs. The system is customized to the size and weight of your inventory and does allow for pallets of different shapes and sizes, unlike other high-density systems such as push-back and drive-in rack. 

Pallet Flow Rack Pluses

• Maximize storage capacity – Get 2x storage vs. Selective rack
• Increase throughput – Separate load & pick aisles reduce traffic and speed pick rates
• Consolidated footprint – Less travel for load and pick activities
• Cost-effective – low per pallet cost vs. other high-density racking
• Better inventory control – Ideal for dated and/or perishable goods (FIFO)

What is Selective Pallet Rack?

Selective Pallet Rack – Back-to-Back Design

Selective rack is often called simple selective because it is essentially vertical uprights connected by horizontal beams to create pallet storage bays. Now a little more engineering goes into the system, but effectively it functions to store palletized inventory in single-deep rows stacked vertically on numerous levels. 

Selective pallet racking allows you to take full advantage of your facility’s vertical space to optimize storage density while maintaining quick, efficient pallet storage and retrieval and 100% SKU accessibility. It is ideal for low-volume, high-SKU inventory. It supports first-in/first-out (FIFO) inventory management and requires a single aisle for loading and pallet retrieval.

Selective rack rows are often placed back to back to reduce the required number of aisles and consolidate space. Additionally, lower levels of the rack system can be equipped with wire decking or other decking options to convert the space for individual item storage. Selective racking is also considerably more affordable than other systems, with minimal installation and maintenance costs.

Selective Pallet Rack Pluses

• 100% SKU accessibility – Single deep storage allows access to each pallet 
• Efficient SKU management – Easily manage a large number of SKUs
• Vertical storage – Utilized vertical cube space vs. floor stacking
• Cost-efficient – Reasonable investment and maintenance costs
• Stores palletized & single items – add wire deck to lower levels to create a shelf for each item storage

Installation and Demolition Service

Nationwide pallet rack installation crews can be an important consideration when purchasing racks, especially for multiple locations. WOI vets all installation crews for safety, insurance, experience, and sound financials. These are essential considerations for any pallet rack purchase that includes installation. Demolition and liquidation service availability are also important considerations when reconfiguring or relocating warehouses and distribution centers. 

Our professional installation team ensures that the finished product meets your expectations, and while we are on the job, you can be sure that we follow strict safety protocols.

WOI Expert Installation:

• 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 schedule a site walk-through inspection — dial (833) 336-7005 or email info@warehouseoptimizers.com. 

Get Help Making Your Warehouse Storage Solution

We realize what is riding on selecting the right storage solution for your facility. You must blend your capacity and operational needs with your budget –we can help.  At WOI, our pallet rack designs are customized to satisfy your unique needs. We work with top-quality manufacturers to ensure durable, long useable life for your pallet rack system. 

The WOI team offers over 180 years of combined material handling experience to ensure your space works to solve your warehousing challenges. Moreover, we are determined to deliver 100% Customer Satisfaction on each project through our Total Satisfaction Experience™ (TSE). 

The Total Satisfaction Experience focuses on five essential customer experiences:

1.     We will listen to your needs
2.     Execute your project with particular 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

We proudly serve customers throughout the Southeast, including KENTUCKY, TENNESSEE, NORTH CAROLINA, ALABAMA, AND FLORIDA.