Pallet Racking to Improve Cold Storage Warehouse Safety

Balancing Warehouse Speed, Safety & Efficiency –Find the Right Pallet Racking Solution

Your cold storage facility contends with unique warehousing challenges. Maintaining consistent temperatures (particularly when loading & unloading), monitoring humidity levels to prevent ice or moisture, and protecting your team from cold exposure are all high priorities. However, at the root of each of these challenges is time –the less time spent with the dock open or accessing inventory, the better chance your team has of managing these challenges. But, faster activity in a busy cold storage warehouse can quickly lead to costly damage and injuries. Anticipate the risk when designing your space, and choose the right pallet racking solutions to handle it.

Cold Storage Safety Concerns

• Forklift speed & abundant activity
• Cold weather gear – less dexterity with bulky clothing
• Slippery conditions 
• Consolidated storage – crowded spaces

Smart Options for Cold Storage Pallet Racking 

The inventory requiring cold storage may surprise you. While most facilities cater to perishable items, a considerable amount of inventory still requires the cold to prevent deterioration. Here’s an overview of standard cold storage inventory. 

Cold Storage Inventory Categories

Whether food or candles, the cost of operating a cold storage facility is the highest among all storage options. Balancing the need for speed with maximizing space… and doing it safely can be accomplished with the right pallet rack solution. For that reason, most facilities look to high-density systems and narrow aisle designs. Still, the system must also provide easy access to the inventory lest you encounter forklift damage that can slow your whole operation down. With the frequent stock rotation required for more date- or time-sensitive inventory, you can plan on a high amount of forklift traffic.

The following systems all pass the cold storage test for function, safety, and capacity –it just depends on your inventory mix, throughput, warehouse space, and equipment as to which system or systems are best for your needs. Using more than one storage rack configuration within the same facility is common.

Mobile Pallet Racking

Mobile pallet racking – maximizes floor space by consolidating the rows of rack and leaving a single aisle open. The rack rows shift side to side, allowing access as needed. Mobile pallet rack can double your storage capacity while saving 40% floor space vs. standard pallet rack.

Drive-in pallet rack (pictured top of page) – tall, narrow lanes create a high-density storage solution and increase space use by up to 90% vs. standard racking. However, drive-in rack requires the forklift to fully enter and exit the rack system exposing the system to a higher risk of strikes.

Pallet Flow Rack

Pallet flow racking – gravity is the driving force behind pallet flow systems. This system creates single SKU storage lanes from 2 to 10 pallets deep pitched from the outside load aisle down to the inside pick aisle. Separate aisles support safe continuous load and pick activity, and the compact design saves up to 60% of floor space vs. standard rack. Pallet flow is a FIFO system ideal for date-sensitive inventory with high-product turnover.

ASRS storage systems – automated storage and retrieval systems (ASRS) are ideally suited to handle the high product turnover of most cold storage facilities and offer a significant reduction in labor and forklifts required for the task. The ASRS process provides substantial protection against inventory, pallet rack, and equipment damage and is the high-density capacity leader. With so many designs available today, finding a system that can scale to your throughput, space, and capacity needs is easy. 

VNA Racking – very narrow aisle racking is very popular with the rising cost of new construction and greater demand for distribution. 

ASRS Storage System

Pallet Rack Design, Check –But What About Installation?

You certainly don’t want to trip on the finish line, so choosing the WOI professional rack installation team is the best way to ensure your project is properly and safely installed. Our pallet rack installers complete over 300 projects per year, and we provide full-service support, including permits, electrical & utility contracting, and fire suppression systems. 

WOI Expert Installation Deliverables:

• OSHA-Trained & Certified Project Managers
• Drug-Free Workplace Certification
• Daily Job Safety Analysis & Jobsite Inspection
• Certified Forklift, Scissor Lift, and Aerial Lift Operators
• TN Licensed General Contractor #00046536 ($1M License)
• Fully Insured

Call today to schedule your pallet rack installation, dismantle, modular building installation, mezzanine construction, and more!

Expert, Turn-Key Cold-Storage Implementation

There are similarities and differences between each pallet storage option outlined above. Depending on your warehouse space, fulfillment goals, and inventory specs, we can help you make the most cost-effective decision. 

If you are considering using AGVs (automated guided vehicles) or AMRs (automated mobile robots) for your inventory stock and pick activities, that will also have a bearing on your decision. 

Contact our warehouse experts to schedule an on-site evaluation, and let’s have a sit-down conversation to outline your warehousing goals, budgetary constraints, and timeline.

When you work with the WOI team, you have access to our combined 180+ years of combined material handling experience to ensure that your solution fully meets your expectations. 

We offer every customer our signature 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

Contact us today to schedule your site inspection — dial (833) 336-7005 or email info@warehouseoptimizers.com. 

Check out our blogs on related topics for more information on warehouse solutions to help manage today’s challenges.

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