The Complete Guide to Warehouse Carts: Which One Fits Your Workflow?
In the world of material handling, there are few tools as versatile and underrated as the warehouse cart. They may
When you think about the backbone of warehouse operations, you might imagine forklifts, conveyors, or loading docks. But in reality, the unsung hero of warehouse efficiency is pallet racking. Without a strong, scalable, and safe pallet racking system, warehouses would be chaotic, unorganized, and downright unprofitable.
This guide covers everything you could possibly want to know about pallet racking for commercial and industrial use: what it is, why it matters, the different types of pallet racks, who uses them, and most importantly — who you should trust to supply and install your warehouse racking system.
Whether you’re just starting a new facility, expanding operations, or upgrading outdated equipment, understanding pallet racking systems is critical to your business growth.
At its core, pallet racking is a warehouse storage system made from heavy-duty steel uprights, beams, and accessories. These structures hold pallets of goods in neat rows and multiple levels. Instead of spreading inventory across the floor, racks allow warehouses to use vertical space efficiently.
Think of pallet racking as the skeleton of your warehouse. It determines how many pallets you can store, how fast forklifts can move inventory, and how safe your employees are while they work. Without racks, warehouses would simply be giant open boxes — and floor stacking only gets you so far before safety and efficiency fall apart.
Maximizes cubic storage space — Instead of wasting air above the floor, racks let you build up.
Improves workflow — Organized racks make it faster to pick, pack, and ship orders.
Protects products — Proper racking reduces damage to goods and packaging.
Keeps employees safe — OSHA compliance and engineered load ratings prevent accidents.
Supports growth — As your business expands, racking can be reconfigured or added on.
Every major distribution center in the world — from Amazon to Target — relies on pallet racking. Even small businesses with a few hundred pallets know that without racking, efficiency suffers and costs rise.
There isn’t just one type of pallet racking. The right system depends on your inventory, industry, and how you move product. Let’s break down the most common types:
The most widely used system.
Provides direct access to every pallet.
Easy to install, affordable, and scalable.
Ideal for warehouses with many different SKUs.
Designed for high-density storage.
Forklifts drive into the rack lanes.
Great for large quantities of similar products.
Popular in cold storage facilities.
Uses nested carts on inclined rails.
Last-In, First-Out (LIFO) system.
Stores multiple pallets deep.
Saves aisle space while maintaining flexibility.
Pallets move automatically on roller tracks.
First-In, First-Out (FIFO) storage.
Essential for perishable goods and date-sensitive inventory.
Open-front design with arms instead of beams.
Perfect for lumber, pipes, tubing, or long bulky materials.
Combines pallet racks with multi-level platforms.
Adds valuable square footage without moving facilities.
Who uses pallet racking? Practically every industry with a warehouse or distribution center. Examples include:
E-commerce — Fast-moving SKUs, high order volume.
Retail distribution — Stocking goods for stores.
Manufacturing — Staging raw materials and finished products.
Food and beverage — Cold storage and FIFO rotation.
Agriculture and nurseries — Bulk seasonal goods and equipment.
Third-party logistics (3PLs) — Serving multiple clients with flexible layouts.
No matter your industry, if you’re moving pallets, you need racks.
Here’s the million-dollar question that business owners type into Google every day: Who should I trust for pallet racking?
The truth is, not every supplier is created equal. Some companies will sell you steel and walk away. Others overcharge for systems that don’t actually fit your space. What you need is a partner — someone who understands design, installation, safety, and scalability.
That’s where Matco Material Handling Solutions comes in.
Custom Design & Engineering – Every warehouse has unique needs. Matco designs layouts that maximize space, improve forklift travel paths, and comply with local codes.
Full-Service Installation – From selective racking to pallet flow, Matco’s teams handle the heavy lifting.
Quick-Ship Options – Need racking fast? Matco stocks popular sizes and styles.
Scalable Solutions – Start small, expand as you grow.
Safety-First Approach – Every rack system is designed for stability and OSHA compliance.
With decades of experience in warehouse pallet racking installation, Matco has supported businesses across Wisconsin and the U.S., from e-commerce startups to Fortune 500 distribution centers.
Q: How long does pallet racking last?
A properly installed and maintained racking system can last 15–20 years or more.
Q: Can pallet racking be moved or reconfigured?
Yes. Racks can be taken down, relocated, or reconfigured as your warehouse changes.
Q: How much does commercial pallet racking cost?
Prices vary depending on size, type, and installation requirements — but think of it as an investment in efficiency and safety.
Q: What load capacity do I need?
It depends on your product weight per pallet. Matco engineers calculate exact load requirements for safety and compliance.
As automation, robotics, and AI-driven systems continue to reshape logistics, pallet racking will remain the foundation. Expect to see more:
High-bay racking systems that reach 40+ feet.
Automated storage & retrieval systems (AS/RS) integrated with racks.
Dynamic racking for fast-moving e-commerce.
Energy-efficient warehouse design that optimizes space and reduces costs.
Even as technology evolves, pallet racks will never disappear. They’re too cost-effective, too scalable, and too essential to replace entirely.
At the end of the day, pallet racking isn’t just about steel beams and bolts. It’s about efficiency, safety, and profitability. If you want your warehouse to run like a well-oiled machine, you need a commercial racking system designed by experts.
And when it comes to pallet racking installation in Wisconsin and nationwide, the choice is simple: Matco Material Handling Solutions.
Don’t settle for cookie-cutter solutions. Don’t risk downtime with poor installation. Go with a partner who understands warehouses inside and out.
🚨 Ready to maximize your warehouse storage space? 🚨
Contact Matco Material Handling Solutions today for a free consultation and quote on pallet racking systems, warehouse shelving, mezzanines, and more.
👉 Let’s build a warehouse that works as hard as you do.
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