Pushback rack systems provide an innovative solution for high-density storage, becoming a go-to choice for warehouses aiming to optimize space and boost efficiency. However, following best practices is essential to reap the benefits and ensure safety.
Discover the do’s and don’ts of pushback racks and master the techniques for implementing and maintaining an effective pushback racking system in your warehouse.
What is a Pushback Rack System?
Pushback pallet racking is a high-density storage solution that allows multiple pallets to be stored multiple racks deep on wheeled carts. When a forklift places a pallet, it pushes back the existing pallets, creating a compact storage arrangement. This system operates on a Last-In, First-Out (LIFO) principle, making it ideal for storing numerous pallets of the same SKU.
The pushback mechanism typically consists of nested carts that move along inclined rails. As pallets are loaded, they push back the carts behind them. When a pallet is removed, gravity causes the remaining pallets to gently roll forward, moving the next pallet to the front. Depending on the system design, this dynamic storage method can accommodate anywhere from two to six pallets deep.
The Benefits Of Pushback Rack Systems
Pushback racking systems offer several major advantages that make them a suitable choice for many warehouses, including:
- Increased storage density. Pushback racks can store more pallets per bay than traditional pallet racking. This is because the system uses a sloped design and carts, eliminating the need for aisles between each pallet position. This space-saving feature is ideal for warehouses with limited floor space or high inventory volumes.
- Improving picking efficiency. Pushback racks are designed to always present a pallet at the pick face, eliminating the need for forklifts to reach deep into racking lanes. This reduces the time required for pallet retrieval and placement. In a busy warehouse environment, these time savings can add up to substantial productivity gains.
- Reducing picking errors. The LIFO nature and dedicated lanes for specific SKUs for pushback racks help reduce picking errors. With each lane assigned to a particular product, the risk of selecting the wrong item decreases, especially in warehouses with similar-looking products or high turnover rates.
The Essential Do’s of Pushback Racks
Implementing a pushback rack system requires following best practices to ensure efficiency and safety. Here are the key “do’s” to keep in mind:
DO: Use for Last-In, First-Out (LIFO) Applications
Pushback racks are specifically designed for LIFO inventory management. This makes them ideal for storing long-lasting products, non-perishable goods, or situations where stock rotation is less critical.
For instance, pushback racks are ideal for storing bulk quantities of the same product, making them perfect for manufacturing environments or distribution centers handling high-volume, consistent SKUs.
DO: Implement Proper Load Distribution
Correct load distribution is vital for the safe and efficient operation of pushback racks. Ensure that heavier pallets are placed at the front of the lane, with lighter ones behind. This practice helps maintain the stack’s stability and ensures the smooth operation of the pushback mechanism.
DO: Conduct Regular Maintenance and Inspection
Regularly inspect your pushback rack system for any signs of wear, damage, or misalignment. Pay close attention to the rails, carts, and upright supports.
If left unchecked, minor issues like loose bolts, worn-out wheels, and bent rails can quickly escalate into safety hazards or operational problems. Schedule routine maintenance to address any concerns and ensure the system remains in optimal working condition.
DO: Prioritize Operator Training
Proper training for forklift operators is vital for safe and efficient use of a pushback rack system. Operators should understand the appropriate loading and unloading techniques, weight limitations, and safety protocols.
This includes avoiding overloading the system, maintaining safe clearance while maneuvering forklifts, and knowing how to handle potential jams without compromising safety.
DO: Ensure Proper Pallet Condition
The integrity of the pallets you use plays a vital role in the performance of your pushback rack system. Damaged pallets and broken boards can compromise the stability of the loaded pallets and potentially cause jams or damage to the rack structure.
Implement a pallet inspection protocol to ensure only sturdy and properly maintained pallets are used within the system.
The Important Don’ts Of Pushback Racks
While knowing the best practices is essential, it’s equally important to be aware of what to avoid when using pushback rack systems:
DON’T: Load Unevenly
Avoid loading pallets unevenly, as this can destabilize the system. Uneven loads can cause carts to tilt or get stuck, disrupting the smooth operation of the pushback rack.
DON’T: Overload The Racks
Each pushback rack system has a designated weight limit. Exceeding it can cause structural damage and serious safety hazards. Always adhere to these limits and review your system’s capacity. Clearly post signage with load and weight limits in visible locations for staff.
DON’T: Use Damaged Pallets
Damaged pallets are a safety risk and can compromise your pushback rack system. Inspect pallets for damage before loading; discard or repair any with broken boards, loose fasteners, or warping. Using damaged pallets can cause jams, misalignment, and damage to the rack structure.
DON’T: Ignore Rack Damage
Don’t ignore even minor damage to your pushback rack system. Regularly inspect for signs of wear, cracks, bends, or misalignment, especially on upright supports, rails, and cart mechanisms. Address any damage immediately to prevent further issues and ensure warehouse safety.
DON’T: Neglect Safety Regulations
Operating a pushback racking system requires adherence to safety regulations established by organizations like the Rack Manufacturers Institute (RMI)
These regulations address weight limits, proper loading and unloading procedures, and forklift operation within the rack system. Familiarize yourself with these safety regulations to maintain a safe working environment for your employees.
Maximize Your Warehouse Efficiency with SRS-i
Pushback rack systems provide an effective storage solution, but it’s essential to understand their strengths and limitations to determine their suitability for your facility. By following the do’s and don’ts of pushback racks, you can optimize these systems to maximize storage density, improve LIFO picking efficiency, and ensure operator safety.
At Shelving + Rack Solutions, Inc., we offer high-quality pushback rack systems and professional design and installation services to optimize your warehouse. Contact us today using our online form to get a quote for your storage project.
