Pairing Forklift Equipment with a Narrow Aisle Pallet Rack Design

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Optimizing Narrow Aisle Pallet Rack Design: A Guide to NA & VNA Forklifts

Narrow aisle pallet rack design refers to a configuration of storage rack that minimizes the system’s overall footprint by narrowing the aisle width between rows. The standard aisle width is approximately 12 feet, but narrow aisles can shrink that width to 8 to 10 feet, freeing up as much as 25% more floor space. Very narrow aisles can be less than 6 feet wide, reducing the rack system footprint by up to 50%. An additional advantage of the narrow aisle pallet rack design is that it allows 100% SKU selectivity vs. other high-density pallet rack systems that rely on deep inventory lanes.

Narrow Aisle Advantages

  • Free up valuable floor space –up to 50%, depending on design
  • 100% SKU selectivity
  • Effective use of vertical cube space

A significant consideration of narrow aisle pallet racking is that it requires specialty lift truck equipment. Standard forklifts require a wide turn radius, which is unavailable in those tight spaces. With several styles of narrow aisle lift vehicles, it’s imperative to pair your rack design correctly with your vehicle. Follow these tips to plan your space and accurately match your material handling equipment.

Narrow Aisle & VNA Forklift Options:

Narrow aisle forklifts and VNA (Very Narrow Aisle) lift trucks are designed for high-density storage environments. Narrow aisle trucks have a standing operator compartment and fork positioned on the side of the vehicle to reduce the turn radius required. Very narrow aisle (VNA) forklifts, such as reach trucks, order pickers, and turret trucks, have unique features and designs for productive operations in confined spaces. 

WOI recommends adding safety gates, guard rails, warning systems, and proper lighting to enhance worker safety in and around the tight workspaces.

A. Reach Trucks

Reach trucks operate similarly to standard forklifts. However, the forklift operator stands (vs. sits down) in the driver cab, consolidating the vehicle size and enabling narrow aisle maneuverability.

Reach trucks have very tall masts and can be equipped with a scissor-like mechanism (pantograph), allowing the forks to extend into deep-reach (double pallet depth) racking.

Advantages

  • Compact design
  • Superior maneuverability
  • Significant height extension
  • Enhanced precision controls
  • Maneuverability in confined spaces
 Considerations

  • Design prioritizes vertical reach over load capacity –confirm max load capacity before choosing a vehicle
  • Stability concerns when operating at elevated heights.
  • Turning radius may be wider than other NA forklifts

B. Turret Trucks

Turret trucks feature a rotating turret head that allows the operator to turn the forks independently of the truck’s chassis. This design provides access to either side of the aisle without repositioning the vehicle. Turret trucks are available as man-up or man-down designs.

As the name suggests, man-up turret trucks feature an operator compartment that moves vertically with the load. Operators access and retrieve items from high storage locations while remaining standing. These vehicles enable hand-picking vs. full pallet loading/unloading.

Man-down turret trucks position the operator at ground level, similar to a standard forklift. The rotating mast allows efficient retrieval and storage of items within the narrow aisle pallet rack space.

Advantages

  • Access both sides of the aisle without moving the truck
  • Turret head rotation enables swift, precise load positioning
  • Flexibility for full pallet or single item loading/retrieval
 Considerations

  • Requires extensive operator training
  • Height restrictions vs. other VNA vehicles
  • Load capacity may be lower than other VNA vehicle choices
  • Complex design may require additional maintenance

C. Order Pickers

Order pickers facilitate the selection of individual items vs. full pallets supporting a high-volume picking application. These vehicles feature a platform that raises the operator to reach items at various heights. 

Advantages

  • Agile, compact design
  • Efficient access to items at extreme heights 
  • Picker has a direct sight line to items
  • Reduced pick time 
 Considerations

  • Requires intensive operator training
  • Used for picking items and cases vs. full pallets
  • Operators must use a harness and safety equipment

D. Swing Reach Forklifts

Swing-reach forklifts are similar to turret trucks and are designed to operate within narrow aisle spaces. They differ from the turret truck because the telescopic forks extend into the rack to secure items beyond the first position. Also, the mast remains stable and does not rotate.

Advantages

  • Valuable in high-density racking storage
  • Full pallet handling
  • Streamlined picking and increased productivity –access to pallets further back
 Considerations

  • Require extensive operator training due to complex steering and dual-mast design
  • Higher upfront costs vs. other VNA vehicles
  • Articulated design may prove challenging in some NA configurations
  • Maintenance costs may be higher due to complex machinery

Importance of Sturdy Racking Systems

Sturdy storage racking systems form the backbone of a safe and efficient warehouse environment. The racks’ structural integrity directly influences the stability and load-bearing capacity. Investing in robust racking ensures the prevention of collapses or structural failures, safeguarding personnel and inventory from potential hazards.

The Warehouse Optimizers Inc’s (WOI) installation team prioritizes safety with meticulous attention to detail and adherence to industry standards. Expert installers guarantee the correct assembly of racks and assess load-bearing capacities and structural integrity, mitigating the risk of collapses or accidents. With a focus on precision and expertise, the WOI team helps you meet your goal for a safe warehouse environment and ensures the longevity and efficiency of the storage system.

WOI Installation Team

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

Implementing Safety Measures within the Racking Structure

Beyond structural stability, incorporating specific safety measures within the racking structure further enhances warehouse safety. This includes safety barriers, safety gates, guard rails, rack guards, and end-of-aisle protectors to mitigate the risk of accidental impacts from forklifts or other equipment. Regular inspections and maintenance routines are crucial to identify and promptly address potential weaknesses or damage.

The WOI team can help you with a comprehensive plan to optimize your warehouse space and function… safely and efficiently. Contact your WOI representative for prompt, personalized support.

Our goal is to deliver Complete Customer Satisfaction on every project, and we back it up with our 5-Step Total Satisfaction Experience™ 

The WOI 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 details of the finished product

Call WOI today — or email info@warehouseoptimizers.com.

Learn More About Narrow Aisle Racking Configurations In Our Related Blog:

4 Critical Installation Tips For Your Very Narrow Aisle Warehouse

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