WOI Risk Rewards Series – Push-Back Racking

Let the Pallets (and Productivity) Come to You with Dynamic Push-Back Racking

High-density pallet storage options typically include drive-in & drive-thru rack, push-back, pallet flow, and ASRS automated storage systems. If you rely on Last-In/First-Out (LIFO) inventory rotation, your options are reduced to drive-in, push-back, and ASRS. Each LIFO storage rack system has benefits and drawbacks, so finding the best solution to meet your needs is where we can help. Take a look at our Risk & Reward blog series for helpful, honest inspections of each pallet storage option. For example, let’s take a closer look at push-back racking.

Let’s Take in the Features of Push-Back Pallet Rack

A push-back system uses deep lanes equipped with side rails that support wheeled carts. The carts stack at the pick face, and the first pallet is loaded on the top cart. The second and subsequent pallets are loaded by pushing back the pallet at the pick aisle. As the pallet is pushed back, a cart is revealed underneath to accept the new pallet. 

Extraction is just the opposite. When a pallet is extracted, the rear cart flows forward to replenish the pick face automatically. The forklift operator controls the speed by carefully loading and extracting each pallet. One big bonus of push-back over drive-in is that the forklift does not have to drive into the rack system, so push-back is typically faster and incurs less damage.

Push-Back Rack Rewards

• Dense pallet storage
• Organized SKU lanes
• Pick face auto replenished
• LIFO inventory rotation
• Easy to operate
• Low maintenance
• Minimal forklift interface (vs. drive-in)

Push-back systems are typically 3-4 pallets deep, but the systems can be built with several levels to produce a high-capacity system within a relatively small footprint. Carts are very durable and can withstand high load capacities as long as the system is designed to handle them.

Push-back is accessed by a single aisle which has benefits and challenges depending on your operation. Single aisles take up less floor space to allow for that valuable space to be used another way. However, you can get congestion in the aisle if your operation stocks inventory and extracts inventory throughout the same shift. Just something to consider… which brings us to some of the system “risks.”

Push-Back “Risks”

• Pallets must be uniform, standard size GMA-style 
• Load capacity cannot vary by more than 500 lbs.
• Not intended for case picking
• Cart wheels can be susceptible to moisture
• Carts can hang up if loose wrap or broken pallet boards are loaded into the lane

Overall the system has many great features and benefits. However, to ensure that it’s the right one for your operation, it’s wise to review the potential drawbacks.

Uniformity of pallets – this is one of those times when the horse actually does have to go before the cart… or, to be more specific, we need your pallet specs before we can design your push-back system. The pallet must securely fit on the cart for the system to be effective and safe. Pallet variations in size or load weight are a no-no in a push-back system.

Full pallet storage – with a lane full of heavy pallets behind the pick aisle, it is not advised to use push-back for case picking. The load weights bearing down on the front pallet can overtake a pallet that is not at full capacity. A great alternative is a pallet flow system.

Wheeled carts – keeping the wheels flowing takes some discipline. As you can imagine, loose wrap, splintered boards, or debris and moisture can affect the free movement of the carts. It is advised to instruct forklift operators to look for dangly items that can derail a cart and cause a major headache, if not an injury.

Ensure Expert Design & Installation for Long-Term, Productive Use 

The Warehouse Optimizers, Inc. (WOI) team is ready to help you find the best storage solution or a combo of systems that will make the most sense for your operational needs. We are a trusted, full-service dealer with decades of experience and hundreds of vendor sources. 

We are dedicated to your complete satisfaction with your project. To ensure we meet those exacting standards, 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.