When planning a warehouse, maximizing your available space should be your priority. Optimizing your warehouse space can improve workflow, increase storage density, and generate more profits.
A well-planned pallet racking layout can also save you money on overhead while reducing the risk of inventory damage and worker injury. One of the best ways to accomplish this is by optimizing the space on your pallet rack.
Select the Right Pallet Racking System
The first step in optimizing your pallet racking is to select the right system for your warehouse. There are several variables to consider when choosing pallet racking systems, including:
Number of SKUs
One of the primary considerations when selecting a pallet racking system is the number of unique SKUs you are planning to store. If you are storing a large number of individual SKUs, you will need to select racking systems that provide a high level of pallet selectivity, such as a drive-in or drive-through pallet racking system.
However, if you store many of the same SKUs, opt for high-density pallet racking. Systems like push-back pallet racking may be a good choice for these types of operations since they provide a low level of selectivity but a high level of storage density.
Number of Pallets
High-density pallet racking is your best choice if you need to store many pallets. Our galvanized pallet racks are made with heavy-duty steel, enabling them to support heavy items. They can be arranged and adjusted as needed to fit the needs of your inventory, making them a good choice for a wide variety of storage businesses.
They are beneficial for businesses that handle a large number of SKUs since they are adaptable to any height, size, or volume. They offer a high-quality and reliable option at a lower cost per pallet position than other pallet racking systems.
Pallet Size and Weight
Ensure your new racks’ weight capacity is sufficient for your inventory. If your facility stores heavy objects – such as industrial materials or automobile parts – you should choose a racking system that is designed with a higher weight capacity.
If you are storing lightweight items – like pharmaceuticals or small electronics – you can choose racking systems with lower weight capacity but a higher degree of flexibility.
For example, our ultra-adjustable tear drop pallet rack frames have varying weight capacities, ranging from 14,000 to 26,000 lbs. Their riveted tear drop design facilitates easy adjustment, meaning warehouses can adjust their racking to fit the dimensions of their inventory. Knowing your average pallet size will help you select a suitable system for your facility’s needs.
Product Types
Ensure you select a pallet racking system suitable for the type of inventory you will be storing. Some products, such as food, drinks, and medicine, may need a high level of airflow to prevent spoilage. These products should be stored using mesh wire decking, which allows for optimal ventilation around the inventory.
There are other considerations aside from airflow. For example, perishable inventory needs to be stored in a first-in-first-out (FIFO) style of inventory management. This method is ideal for perishable products with a high turnover and prevents spoilage.
Maximize the Vertical Space
One of the best ways to maximize your warehouse’s storage density is to optimize available vertical storage space. By using your warehouse’s vertical space, you can store a higher number of pallets in the same facility, saving you money on overhead and improving your profitability.
Over the long term, efficient use of your warehouse’s vertical space can also prevent the need for a costly expansion or relocation to a larger warehouse facility.
Determine How Much Space is Available in Your Facility
The first step in optimizing your storage facility’s use of vertical space is to take a detailed inventory of your warehouse or storage facility. You should examine how much vertical space is available for pallet storage and determine where it can be better utilized. To do this, you may need to measure your warehouse’s dimensions.
While you should strive to optimize your facility’s available space, you should also avoid overcrowding. If you do not leave enough room in your facility to provide adequate aisle and overhead space to comply with safety guidelines, you risk increasing the forklift accident occurrence rate and decreasing worker productivity.
To prevent this, you will need to provide sufficient clearance for sprinkler systems to operate in case of a fire and enough room in forklift access aisles for equipment to navigate safely.
Reassess Your Facility’s Layout
As you assess your facility’s level of available space, you can also consider the overall layout of your facility. Determine if there are any inefficiencies in your warehouse workers’ workflow and if they can be fixed through reorganizing the warehouse.
Consider Your Inventory
You should also consider the nature of your inventory. One minor drawback to using high-density racking systems is that the items stored on the upper rack levels are more difficult to access than items stored on lower racks. To prevent this, you should categorize your SKUs by sales volume: place less popular inventory higher on the rack and place SKUs that are more popular in lower, more accessible areas.
You should also consider the weight of your inventory as you decide where it will be stored. Heavier inventory should be stored on lower shelves, with lighter inventory on the upper levels. If heavier objects are stored on the upper shelves, a change in weight distribution can lead to the rack tipping and collapsing. This can cost your facility thousands in material and inventory damage and potentially injure employees.
Find a Racking System That Fits Your Needs
If you need to make more efficient use of your vertical space, invest in racks designed to be stacked several layers high.
For example, our Tier-Rack Dyna-Pallet stacking frames are ideal for warehouses that need to increase their vertical space usage while storing crushable or easy-to-damage items. The frames can be stacked several levels high and have a weight capacity of over 2,000 lbs, making them an excellent choice for various warehouse settings.
Use Static and Dynamic Pallet Racking
While there is a huge variety of pallet racking types, they can be broadly divided into two main categories: static and dynamic pallet racking. To make the most of your warehouse, consider using both types of racking simultaneously.
Static Pallet Racking
A static pallet racking system is designed to store inventory without moving it. Functionally, these racks behave like shelves, providing the inventory with a safe and easily-accessible storage location without moving the pallets.
Typically, these racks have a significantly higher weight capacity than dynamic pallet racking systems and are highly adjustable to fit the needs of your inventory. A good example of a static racking system is our Tennsco bulk storage racks, which are adjustable by 2” increments and can support 3,800 lbs. per rack.
Dynamic Pallet Racking
Dynamic racking is designed to store and move inventory. Some dynamic pallet racks, like pallet flow racking, use gravity and wheeled carts to move pallets as new inventory is added or old inventory is retrieved. Other racks may use devices like conveyor belts or bots that move the inventory as needed.
There are dynamic racks available for every type of storage system, whether you need a high degree of selectivity or a system that operates using the first-in-first-out style of inventory management. They serve to improve workflow by making inventory more readily accessible and are particularly useful for high-volume operations.
By using a combination of both racking types, you can optimize your warehouse’s workflow. For example, you can use static racking for reserve inventory while using dynamic racks for items that need to be accessed for processing or shipping.
Items can be moved between the racking types as needed. You can maximize your space utilization (by using high-density static racks) and optimize your facility’s workflow (by using dynamic racking systems).
Reduce Aisle Space
Another primary consideration when planning a warehouse’s layout is the required aisle space. Many warehouses make the mistake of overestimating the amount of space necessary in access aisles. While it is essential to provide sufficient space for forklifts and material handling equipment to operate safely, providing excess aisle space can limit your warehouse’s overall storage volume.
Determine the Minimum Amount of Aisle Space Necessary
To optimize your warehouse’s aisle space, you should first consider the size of any forklifts or material handling equipment you use. You should provide enough room for this equipment to easily traverse the aisles, turn around, and access pallets. You should also ensure enough space in the aisle for both a forklift and workers on foot to coexist.
However, if the access aisles are too tight, you risk increasing the number of forklift accidents, which can injure employees, damage inventory, and destroy racking systems.
To calculate the ideal aisle width, take the forklift’s right-angle stacking width, add the average load length, and add 12” for clearance.
Comply with Safety Standards
You should also ensure that your aisles are wide enough to comply with applicable OSHA standards, such as OSHA’s 1910.178, which regulates forklift operations. Under these standards, if you install any narrow aisles, you must ensure that they are properly labeled with signs and notices.
There are also requirements for minimum spacing between pallet racks; fortunately, many accessories can help you stay in compliance. For example, roll-formed row spacers, like our Tri-Boro row spacers, will separate your pallets by a consistent distance.
Consider Mobile Pallet Racking
If your forklift access aisles greatly reduce your facility’s inventory capacity, you can also consider switching to mobile pallet racking. With mobile pallet racking systems, pallet racks are placed on mobile bases that are moveable using pre-fixed tracks. They operate using a motor, moving the pallet racks to allow access as necessary.
With mobile racking systems, you’ll no longer need to create designated access aisles; instead, the pallet racks move to create an access aisle for forklifts. This dramatically increases storage density while providing a high level of accessibility.
Invest in Adjustable Racking
Another way to maximize your facility’s use of space is to invest in adjustable pallet racking systems. Many static pallet racks are highly adjustable, which allows you to reconfigure your racks to fit the needs of your inventory.
This is particularly valuable for warehouses that handle a wide range of SKUs or constantly-rotating inventory. Investing in adjustable racking systems means you don’t need to purchase new ones as your inventory evolves. You will also be able to store more items per rack shelf, improving storage density.
Boltless adjustable racking systems are designed to be easily reconfigured, so you won’t need to hire third-party specialists to adjust to changes in your inventory.
For example, our tear drop pallet rack frames are fully customizable and easy to adjust since the frames include teardrop-shaped slots. This design allows everyday warehouse workers to adjust the rack as inventory changes, eliminating the need for potentially costly third-party racking adjustments.
Boost Productivity in Your Warehouse With Shelving + Rack Systems, Inc.
No matter how productive and profitable your warehouse is, you can always improve. The project managers at Shelving + Rack Systems, Inc. can help identify weak points in your warehouse operation and work with you to devise a plan to address them.
We carry various pallet racks and pallet rack accessories. We can even install and inspect your new racks so you can upgrade your storage system easily for improved workflow, increased storage density, and higher profit margins.
Call Shelving + Rack Systems, Inc. today at (800) 589-7225 to see how our team can help improve your warehouse operation with intelligent racking solutions.
