In the highly competitive warehouse industry, it’s necessary to remain abreast of the latest developments and strategies in the field to maximize your use of available storage space, increase order-fulfillment efficiency, and improve inventory management. This is even more important today due to the increased demand for online goods and shortages of shipping containers.
Changing Racking Needs
The ongoing global pandemic has strained international supply chains and caused a significant increase in e-commerce. At the same time, workplace rules have changed to allow for social distancing, including in warehouses and distribution centers.
This has reduced usable storage space, increasing its value. As a result, many warehouses have had to adapt by upgrading their storage systems to increase picking and throughput efficiency to remain competitive while keeping their workers safe.
What has changed more than anything is the need for warehouses to remain flexible in the face of supply-chain disruptions and sudden shifts in consumer demand. To meet the rapidly changing conditions that warehouses face on a daily basis, companies that manufacture storage systems have had to design racks to be modular. The modular setup allows businesses to configure and dismantle them as needed. This simplifies relocation and adjustment, factors that have become more important in the last few years.
In addition, warehouses have had to consider everything from automated storage and retrieval systems (AS/RS) and robotics to sophisticated warehouse management software (WMS) to ensure orders are fulfilled efficiently.
Pallet Racking Systems
Modern warehouses use a wide variety of racking systems to store inventory in an organized manner for timely retrieval. This keeps merchandise protected, off the floor, clean, and ready for dispatch.
One of the most commonly used types of racking system, for example, is the selective rack. This is a low-density rack designed for low-volume storage where required selectivity is high. Inexpensive and easy to assemble and install, selective racking allows your workers to immediately identify and retrieve the inventory items they need.
Used selective racking is also one of the best options for warehouses that operate on a strict budget or are newly established.
However, selective racking is unsuitable for warehouses that require high-density, high-volume storage solutions to reduce the footprints of their racks. As warehouses strive to increase storage capacity, other options are needed.
High-Efficiency Alternatives to Selective Racking
In addition to standard selective racking systems, there are several types of used warehouse pallet racking systems you can choose from to maximize the efficiency of your business and increase the space available to you while operating on a budget.
Pallet flow racking
If you need to increase the storage density of your warehouse, used pallet-flow racking is a high-density FIFO (first in, first out) system that stores palletized inventory items on roller or wheel lanes that are inclined.
This allows the system to transport pallets from the rear charging face to the front discharging face. Pallet-flow racking also protects workers, as forklift drivers load the rack from the opposite side.
Carton flow racking
Designed for use with cardboard cartons, the underlying principle is similar to pallet flow racks: Inventory items slide along inclined roller lanes from the loading to the unloading face. The difference, however, is the picking or retrieval method.
Used carton flow racks are intended for use with human order pickers, whereas pallet flow racks are intended for use with forklift trucks. Both methods can significantly increase your warehouse’s throughput and order-fulfillment efficiency, especially if you integrate conveyor belts into the process.
Wire Shelving
Wire shelving is useful for light- to medium-duty storage needs, combining high accessibility and visibility. Wire shelving allows air to freely circulate between inventory items and shelves, keeping goods fresh longer. If you store food items, investing in used wire shelving is a good choice. The open mesh design also allows water to penetrate the system, so fire-suppression systems can effectively extinguish nascent fires before they grow.
If you need shelving for relatively small, lightweight items for retrieval by human order pickers, used wire shelving units can be a cost-effective solution. Stationary or available with caster assemblies, you can choose the units that make the most sense for your warehouse.
Cantilever Racks
Of course, if your warehouse needs to store non-palletized inventory items that are awkwardly shaped, long, and heavy, that’s what cantilever racks are for. Cantilever racks are ideal for storing furniture, drywall sheets, metal tubing, pipes, bar stock, and lumber. Part of staying up-to-date regarding warehouse management is using the most appropriate racking and shelving systems for the inventory that you store, even when you’re shopping for a gently-used model to save money.
Consider Automation Technologies
Automated storage and retrieval systems (AS/RS) play an increasingly important role in modern warehouse and distribution center operations. Using computer-controlled systems to place inventory items in, and retrieve them from, designated storage locations, an AS/RS can significantly improve loading and order picking accuracy, workplace safety, and throughput efficiency. When shopping for used shelving racks for your warehouse, look for AS/RS in the following configurations:
Vertical Lift Modules
A vertical lift module, or VLM, is a fully enclosed AS/RS consisting of two vertical columns and a center extractor. Trays containing inventory items are located in the two vertical columns. When a worker requests a tray, the extractor retrieves it and delivers it to an access point, such as a picking window. The worker then decides whether to pick or replenish the stock in the tray, and the extractor returns the tray to a position in one of the two columns.
VLMs allow you to reduce the footprint of your storage systems while increasing your storage capacity. If your floor space is limited and you need to expand your storage, consider a VLM.
Vertical Carousels
Resembling a Ferris wheel mechanically, the vertical carousel is an enclosed AS/RS that uses a series of carriers rotating on a chain drive to deliver inventory items to an access point for restocking or retrieval. This is usually a picking window or workstation located at an ergonomic height, reducing worker strain.
While vertical lift modules and vertical carousels increase storage density, VLMs are the heavy-duty option, capable of supporting more weight per carrier than vertical carousels.
Horizontal Carousel
A horizontal carousel consists of a series of bins or carriers that rotate on an oval track. A motor powers the carriers on the track, which move horizontally. Horizontal carousels can improve worker productivity and picking accuracy while increasing storage density.
Integrating a pick-to-light system can increase picking accuracy further, as LED displays direct the worker to the needed item. This also reduces labor costs and the time required to locate and retrieve products.
It’s also possible to integrate conveyor systems with horizontal and vertical carousels and vertical lift modules to replenish stock and dispatch orders.
Cost of Automation
Whether a used AS/RS is right for your warehouse depends on the inventory items you need to store and dispatch, the volume, the turnover rate, and your budget. VLMs are generally more expensive than horizontal carousels, which represent a low-cost alternative. However, for either system to be a worthwhile investment, you must evaluate your needs and the layout of your warehouse to ensure the ROI is sufficient.
Dimensioning Systems
Another way to improve warehouse efficiency when time is a factor and cost-cutting is critical is correct dimensioning. Manual box and pallet dimensioning, which workers typically perform in the receiving area of a warehouse, can be an inefficient and time-consuming process. To reduce time spent on this activity, and the possible errors that may result from manually recording this information, consider installing an automatic dimensioning system. A dimensioning system can measure the weight and volume of your inventory items, entering this information into the warehouse receipt.
Consider Installing a Mezzanine
When additional storage space is critically needed, but expansion or relocation is not viable, you can consider installing a mezzanine. A mezzanine is an intermediate platform or floor between the main floor and ceiling that is partly open. Usually accessible via a stairway, mezzanines can increase the storage capacity of your warehouse, providing additional space for shelving, racking, or floor stacking.
Invest in a Warehouse Management System
A warehouse management system (WMS) is a vital part of many modern warehouse operations, allowing you to track, log, and manage your inventory more efficiently. Although warehouse management systems are digital, they can be used with automated material-handling systems to increase warehouse-wide efficiency.
Warehouse management systems are usually used with barcode scanners or RFID (radio frequency identification) tags.
Find the Best Solution to Your Warehousing Needs
Whether you decide that the best way to stay up-to-date is to upgrade your storage racks or install automated storage and retrieval systems, Shelving + Rack Systems, Inc. can help. Used shelving is easier than ever to assemble and disassemble, compatible with technology or mobile to meet the demand of a modern warehouse.
Alternatively, you may decide you need to re-evaluate your warehouse storage strategies or integrate a warehouse management system.
If you are just starting or expanding your warehouse, contact us about used shelving or racking systems, and we can help you configure your warehouse layout.
