Designing a new distribution center is a complicated process involving numerous factors that must be addressed to ensure success.  After observing thousands of rack system project installations, below are a few common mistakes that we have seen made during the design process that either delay or slow the opening of the facility, or longer term affect the overall efficiency and safety of the facility. 1.  Loads to be stored are not clearly defined: Everything in a distribution center revolves around the loads that need to be stored, and the pallets that they are placed on.  It is critical to be sure […]

When distribution facility operators are looking to densify their storage layout (store up to twice as many pallets in the same facility when compared with selective rack), many times Pushback Rack systems can be an excellent alternative.  A pushback rack system is a LIFO system, normally composed of an inclined rail section that extends the full depth of the storage lane (typically from 2-6 pallets deep).  There are a series of nested carts that the pallets rest on top of that roll on the rail system (either C channel or tube construction).  For a two deep system, there will be one […]

There are many different types of pallet racking configurations that can be selected by end users depending on their storage needs. They range from  low density selective rack all the way to high-density pushback , drive in, and pallet flow systems. Each configuration has advantages and disadvantages: Selective Pallet Rack: Single selective pallet rack is the most common style of rack system. It is low cost, readily available and provides access to every pallet. The down side is that nearly 50% of the facility is dedicated to aisle space (typically 9-12′) and density is sacrificed. Narrow Aisle: Narrow aisle rack is […]

A pallet rack system’s basic function is to help warehouse operators to improve the storage density of their facilities by storing pallets vertically to make use of the vertical space in the warehouse efficiently.  Pallet racks can be configured in a wide variety of ways to meet customer’s needs ranging from low density, high selectivity selective systems to high-density pushback, drive in and pallet flow systems. There are two major core construction materials used to construct pallet rack systems, roll form steel and structural steel. Roll Form Construction:  Roll form rack is built by taking a coil of light gauge steel […]