Case Study: Customizing Super Sack Storage for Push-Back Racking

Solving Super Sack Storage Challenges with Tailored Push-Back Racking Systems

Anyone who has ever picked up a full grocery bag knows that when the items inside aren’t evenly distributed, the bag sags in the center. Yet, when you place the bag on a sturdy surface like a countertop, it will even out and support the bag. However, if you place that bag on a cushioned chair, the chair will absorb the sag. The same principle applies when storing super sacks in a warehouse. Super sacks are used for storing dry bulk materials like seeds, grains, or powders, but they are given to sagging if not properly supported. For one of our customers, this scenario led to a significant challenge when storing super sacks within a push-back racking system. However, with a little ingenuity, the Warehouse Optimizers Inc (WOI) team developed a custom solution to keep the operation running smoothly and safely. Here’s our inside scoop to help you avoid this same challenge.

The Challenge

Super sacks, also known as bulk bags, are large containers capable of holding thousands of pounds of dry goods. Unlike rigid containers, super sacks require some sort of stabilization when being stored within a dynamic racking system such as push-back rack. Pallets often suffice for this purpose; however, as we discussed in our recent blog series on pallets, not all are created equal when it comes to supporting different load types, even if they have the same capacity rating.

The material of the pallet plays a crucial role in ensuring effective load conveyance and stability. While plastic and softwood pallets may meet the required load capacity, they are more prone to sagging. In contrast, well-built hardwood or metal pallets offer more reliable support.

This is exactly why our customer reached out for a solution with their push-back racking system. The super sacks, each weighing up to 2,500 pounds, were placed on wood pallets for storage. While the pallets were strong enough to carry the weight, the concentrated load in the middle caused the pallets to sag. Push-back rack systems use wheeled carts to transport pallets within the storage lanes, but the sagging resulted in the pallets deflecting as they moved, disrupting the flow and stability of the entire system. This issue affected both safety and operational efficiency.

The Solution: Stabilizing the Pallets with Custom Modifications

While replacing all the pallets could have been an option, the more economical solution in this case was to modify the push-back carts by adding supports to the top of the push-back cart.  Multiple options were available including wire decking, added deck supports, and bar-grading decking. These provide additional support, helping sustain the pallet load on the cart, enabling smooth back-and-forth movement, and preventing deflection.

Understanding Super Sacks and Push-Back Rack Systems

A push-back rack system is a highly efficient storage solution that allows up to 5 pallets deep per lane. Wheeled carts move the pallets back and forth along steel rails within the lanes. The carts sit in a stack at the front pallet position within each storage lane. To load a pallet, the forklift operator places it on the top cart. To load the second pallet, the operator pushes the first pallet back, revealing the next wheeled cart. The process continues with the final pallet resting directly on the rails. To extract pallets, the forklift operator secures the pallet at the pick aisle and then carefully backs up and away. Gravity flows the rear pallets forward to refill the pick aisle position. This Last-In/First-Out (LIFO) inventory system ensures that the most recently loaded pallet is the first removed.

If the pallet load is warped or point loaded instead of uniformly distributed, you will likely encounter flow disruption and risk the safe operation of your system.

Key Considerations for Super Sack Storage on Push-Back Racks

When designing a push-back rack system for super sacks, several key factors must be taken into account:

• Pallet Stability: Super sacks can cause pallet sagging, affecting the pallet’s integrity and disrupting the system’s flow. Pallet stabilization is critical to maintaining smooth operation. 
• Load Distribution: Even distribution of weight across the pallet is essential for efficient operation. Super sacks, especially those containing loose or liquid materials, require extra attention to ensure that the weight doesn’t shift or cause uneven pressure on one part of the pallet. 
• Push-Back Cart Design: The carts must support heavy loads without warping or degrading. Custom modifications like wire decking can help prevent sagging and stabilize the pallet, ensuring consistent flow and smooth operation. 
• Uniform Pallet Size and Weight: For a push-back system to function properly, you must use uniformly sized pallets and load weights.

The Benefits of WOI’s Custom Push-Back Rack Solution

By modifying the push-back carts to incorporate wire decking, WOI provided the customer with a customized solution that addressed the sagging issue and improved the flow of goods within the system. The result was a stable, efficient push-back racking system that allowed the customer to safely store and retrieve super sacks without disrupting the overall operation.

WOI’s Commitment to Safety and Quality Installation

At Warehouse Optimizers, Inc. (WOI), safety is our top priority. We understand that a poorly installed pallet racking system can endanger employees, inventory, equipment, and infrastructure. That’s why we offer professional installation services to ensure the integrity and security of your warehouse systems.

With over 300 installations completed annually, our experienced team handles everything from permitting to final sign-offs, ensuring a seamless project execution. Our professional installation team includes OSHA-trained project managers, certified forklift and aerial lift operators, and a commitment to maintaining a drug-free workplace.

The WOI Total Satisfaction Experience™

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When you partner with WOI, you receive more than just design and installation expertise—you get a dedicated team committed to your success. Our WOI Total Satisfaction Experience™ includes:

• Listening to Your Needs: We take the time to understand your unique challenges and requirements. 
• Executing with Precision: Our expert team ensures your system is tailored to your exact specifications. 
• Adhering to Timelines: We respect project deadlines to minimize disruptions and maximize efficiency. 
• Ensuring Safety: Every aspect of our work prioritizes safety for your employees and operations. 
• Attention to Detail: We meticulously oversee every phase of the project to deliver a flawless installation.

Improve warehouse efficiency and safety with WOI’s comprehensive pallet flow solutions and expert installation services. Contact us today to discuss your next project!

WOI Service Areas

Nashville TN, Knoxville TN, Clarksville TN, Memphis TN, Chattanooga TN, Johnson City TN, Huntsville AL, Birmingham AL, Bowling Green KY, Asheville NC, Charlotte NC, Kalamazoo MI, South Bend IN