Guide to Pallet Racking Types

• Low cost of installation and maintenance.
• Excellent accessibility and SKU visibility.
• Simple to install, reconfigure, or expand.

Ideal Use Cases:

• General warehousing.
• E-commerce fulfillment.
• High SKU variety, moderate throughput.
• Inventory Flow: Supports both FIFO and LIFO, depending on how product is loaded and unloaded.

 Drive-In and Drive-Through Racking

• Single-entry design.
• Operates on a LIFO basis.
• Pallets are loaded and retrieved from the same side.

• Dual-entry access (loading from one end, retrieving from the other).
• Supports FIFO flow.

• Maximizes storage density by reducing aisle space.
• Ideal for storing large quantities of the same SKU.

• Cold storage.
• High-volume, low-SKU environments like beverage or canned goods distribution.

• Requires skilled forklift operation.
• Not ideal for fast picking operations.

Push back systems use a series of nested carts on inclined rails. Pallets are loaded from the front and pushed backward as new ones are added.

How It Works:

• When a pallet is removed, the one behind it rolls forward.
• Operates on a LIFO basis.

• Greater density than selective racking.
• Faster access than drive-in systems (no need to enter the lane).
• Reduces number of aisles needed.

• Medium-turn inventory.
• Fewer SKUs with multiple pallets per SKU.

Pallet Flow Racking

• Operates on a FIFO (First-In, First-Out) basis.
• Pallets are loaded at the rear and flow forward via gravity as each one is picked.

• Maximizes throughput for high-volume, fast-moving products.
• Ideal for environments requiring strict inventory rotation.
• Reduces travel time for forklifts.

• Food and beverage distribution.
  Pharmaceutical operations.
  Any inventory sensitive to expiration or aging.

Cantilever Racking

Cantilever racking is designed specifically for storing long, bulky, or awkwardly shaped items.
Structure:

• Uprights with arms extending out—no front columns.
• Provides unobstructed access to loads of varying lengths.

• Easy loading/unloading of long materials like lumber, steel, or pipes.
• Customizable arm lengths and load capacities.

• Building materials.
• Furniture.
• Industrial manufacturing components.

Double-Deep Racking

• Pairs of selective racks placed back-to-back.
• Second pallet is stored behind the first, limiting access.

• Increases storage capacity by up to 30% over selective systems.
• Fewer aisles required.

• Reduced accessibility (only front pallet is directly accessible).
• Higher forklift skill and equipment cost.

• Warehouses with low SKU variety and high pallet counts per SKU.

Pallet Shuttle and AS/RS Systems

• Use semi-automated carts to move pallets within deep lanes.
• Forklifts place and retrieve shuttles at entry points.
• Often operate on LIFO, though FIFO is possible with dual-lane setups.

• Use cranes, shuttles, or robots to automatically place and retrieve loads from high-density racking.
• Fully integrated with Warehouse Management Systems (WMS).

• Drastically reduces labor.
• Enables lights-out operations in some cases.
• Scales easily as business grows.

• High-throughput, high-SKU operations.
• Cold storage or high-value inventory.
• Companies investing in warehouse automation

When selecting a pallet racking system, it’s important to understand the two primary types of rack construction:

• Roll-Formed Racking is made from cold-rolled steel and formed into shape. It’s lighter, easier to install, and often more flexible for reconfiguration. It’s commonly used in warehouses where product mix changes frequently or adjustments are needed over time.
• Structural Racking is made from hot-rolled steel and bolted together. It’s more durable, impact-resistant, and suited for heavy-duty applications like high-traffic areas or refrigerated environments where forklifts frequently bump racks.
  

When to Choose Which:

• Use roll-formed when agility, cost, and ease of adjustment are priorities.
• Use structural when durability, impact resistance, and long-term load stability are critical.
  

Cold Storage Racking Considerations: 

• Material performance in sub-zero environments is critical—components must resist brittleness and corrosion.
• Condensation must be managed to avoid slip hazards and protect inventory.
• Efficient aisle design helps minimize door open times and conserve energy.
• High-density systems like drive-in, pallet flow, or shuttle systems are typically favored to maximize cube utilization in costly refrigerated spaces.

• Heavier-duty anchoring and wider base plates
• Reinforced bracing between uprights
• Engineered rack designs validated through seismic testing

• What is your throughput rate?
  High-turnover operations may benefit from systems like pallet flow or GTP-integrated AS/RS, while lower velocity SKUs may be fine with selective or double-deep racking.
• Do you need selective access to every SKU?
  If yes, selective racking is a better fit. If not, consider high-density solutions like push-back or drive-in to maximize space.
• Is automation part of your future plans?
  Your racking system should be compatible with technologies like AGVs, shuttles, and robotic picking arms. Planning for automation early reduces retrofit costs later.
• What are your safety and compliance requirements?
  Local fire codes, OSHA guidelines, and seismic regulations all influence racking design and installation. Choosing a compliant system ensures long-term operational stability.
• What are your load capacity requirements?
  Oversizing rack load capacities is a common and costly mistake. While it may seem safer to overbuild, the added structural requirements can lead to unnecessary capital expense without added operational benefit. Understanding your product weight distribution and planning for realistic max loads ensures cost-effective, safe designs.

• Example layout: Use selective racking for fast movers and high-access SKUs, push back racking for reserve inventory, and cantilever racking for oversized or irregular items.
• Integrating AS/RS systems: For high-density zones or automation-ready sections, integrating an Automated Storage and Retrieval System (AS/RS) alongside traditional racking can dramatically increase throughput and reduce manual handling. These systems are especially effective for slow- to medium-movers or environments where space and labor efficiency are top priorities.
• Zone-based strategies: Segmenting by product velocity, order profile, or environmental needs (e.g., cold storage) helps create efficient zones with the right racking solution for each.