From Selective to Drive-In: The Top 9 Pallet Racking Types Explained

A Pallet racking is an essential storage management system with an upright structure made of steel. It consists of beams and connectors combined with bolts, welding, or clips to store the inventory safely. There are different types of racking systems for warehouses.

However, not all pallet racking types are suitable for all businesses. It would help if you found the right kind to improve productivity, efficiency, and accessibility. It will also reduce inventory wastage.

So, understand types, their layout and structure, capacity, stock management facility, and cost before choosing one. Each pallet has different key benefits for the warehouse racking system. Here are 9 types of pallet rackings.

Save Space and Time: The 9 Best Types of Pallet Racking for Your Business

1. Selective Pallet Racking

Selective pallet racks are the most common warehouse racking. It provides direct access to the inventory without moving any pallets. The selective rack is adjustable and customizable to meet different inventory needs according to size and weight. They are also suitable for various types of forklifts. Here several selective pallet racking advantages. 

 

Pros	Cons
Provide direct access to inventory	Lower storage space
Adjustable with weight and size	Inefficient use of vertical space.
Cost-effective	Not perfect types of pallet racks for businesses with higher storage needs.
Simple installation
Easy load and unload

Suitable for:  A wide variety of SKUs and high turnover rates like retail, general warehousing, and distribution centers.

Stock management: Selective Pallet rack is suitable for Both FIFO and LIFO

 

2. Double Deep Pallet racking 

Double deep racking is a kind of selective racking with higher storage capacity. The pallets are stored two deep to increase the storage. However, this will sacrifice direct access. But it offers simple access to the inventory that ensures quick loading. 

Pros	Cons
Highly efficient for loading and unloading.	No direct product accessibility like selective racking
Robust system to handle heavy inventory	Require special forklifts to operate
Easy assembly and low maintenance
Adjustable with inventory needs
Better space utilization

 

Suitable for: Distribution centers with moderate turnover or Higher store capacity needs with the same SKUs.

Stock management: LIFO (Last In, First Out)

 

3. Back Racking / Push-back racking systems

Push-back or back-racking is another high storage racking method where pallets are stored 2 to 6 deep. The pallets are loaded from the front and pushed back when new pallets are stored. When the new pallets are removed, the remaining pallets are rolled forward for removal or access.

Pros	Cons
High-density storage system compared to selective or double-deep racking.	Limited to LIFO only
Suitable for various products	Higher initial cost
Efficient space utilization
Minimal aisle space requirement
Reduce forklift travel for added safety

Suitable for: Warehouses with medium yet efficient inventory turnover needs.

Stock management: LIFO (Last In, First Out)

 

4. Pallet Flow Rack

Pallet flow racking is a dynamic system that uses gravity to move pallets from one end to another. The inclined rails tracks allow pallets to move forward when front pallets are removed. It reduces the handling time and increases the stock rotation.

Pros	Cons
High storage capacity.	Limited product variety
Auto and fast stock rotation.
Higher efficiency in stock management.
Reduce aisle requirements
Low maintenance

Suitable for: Industries with high turnover rates, such as food distribution centers and beverages.

Stock management: FIFO method (First In, First Out). 

 

5. Drive-In/Drive-Thru Rack

A drive-in/drive-thru rack is a high-storage racking system where pallets are stored multiple positions deep. Drive-in pallet racks have single entry points, whereas drive-thru rackings have double entry and exit points for both sides of access.

Pros	Cons
Cost-effective yet large storage solution	Limited selectivity
Bulk storage benefits	Risks of damage due to forklift traffic
Efficient space utilization
Simple structure with minimum maintenance
Minimizes the load for aisle

Suitable for: cold storage, bulk storage, or limited SKU type.

Stock management: FIFO (First In, First Out)

 

6. Roll Formed Cantilever Rack

Roll Formed Cantilever Racking is a special rack system for bulky or long items like pipes, lumber, and furniture. The system has vertical columns with horizontal arms extending outwards. It creates an open space for products and is highly adjustable according to size and weight.

Pros	Cons
Suitable for long and bulky size	Not suitable for standard-sized pallets
Highly adjustable	Higher initial cost
Open design
Higher storage capacity
Versatile product suitability

Suitable for: Construction materials, furniture, metal, and pipe

Stock management: Suitable for inventory not managed by FIFO or LIFO. 

 

7. Mobile Pallet Racking

Mobile pallet racking is a highly adjustable racking system where the pallets are located on mobile bases and can be moved. It eliminates the need for fixed aisles to let the racks move where needed. This is highly suitable for businesses with limited warehouse spaces.

Pros	Cons
High storage density	Require regular maintenance
Dynamic accessibility	High initial cost
Versatile and adjustable space
Higher safety and lower product damage
Energy efficient

Suitable for: cold storage, limited spaces

Stock management: FIFO (First In, First Out)

 

8. Shuttle Racking

Shuttle racking is a semi-automated storage system with a motorized shuttle that allows auto pallet transport within the rack. The automatic shuttle reduces the forklift involvement to save labour costs.

Pros	Cons
Automatic system to ensure higher efficiency	Complex maintenance
Reduce labor cost	Limited SKU variety
Fast loading and unloading
Improve stock control
High-density storage system

Suitable for: Large volume of the same SKU

Stock management: LIFO (Last In, First Out), but best for inventory not managed by FIFO or LIFO.

 

9. Carton Flow Racking

As the name implies, carton flow racks are designed for small to medium-sized cartons and boxes. It features slightly inclined gravity-fed roller tracks to ensure easy flow for faster loading and unloading. 

Pros	Cons
Efficient Stock Rotation	Limited to small to medium items
Fast loading and unloading	Higher initial cost and higher maintenance
Higher accuracy and less picking error
Easy replenishment
Versatile storage option

Suitable for: Ideal solution for high-volume order picking

Stock management: Suitable for FIFO

 

FAQs On What are the different types of pallet racking ?

What factors should I consider when choosing a pallet racking system?

Consider the size and weight of your inventory, storage density requirements, access needs, budget, warehouse layout, FIFO or LIFO inventory management, and any other specific needs.

 

Can pallet racking be used in cold storage facilities?

Yes, you can use pallet racking in cold storage facilities since they can handle low temperatures and high humidity levels.

 

How much weight can a typical pallet racking system support?

A pallet racking system can support 1500 to 5000 pounds, depending on the type of racking.

 

What is the cost range for different pallet racking systems?

The cost can vary from $60 – $500 per pallet, depending on the type of racking and pallet you use.

 

How do I ensure the safety of my pallet racking system?

Proper installation, regular inspection and cleaning, proper load capacity, and sufficient training and safety for workers will ensure the safety of your pallet racking system.

Wrapping up

A good pallet racking will ensure an efficient and safe storage system. Make sure to choose the right type of pallet for your needs. Consider the storage requirement. Calculate the installation, maintenance, and operation costs. Measure your area and check your inventory type to find the right pallet racking for your business.

Matco Distributor provides an all-in-one solution for storage. Contact Matco to Maximize Space and Improve Inventory Flow.