Drive-in Pallet Racking

Drive-In rack systems provide a low-budget and high-density storage solution for customers with lower SKU counts.  Drive-In rack systems load from the back to the front (First-In Last-Out) as the forklift literally drives into the rack system, loads the pallet onto rails and backs out of the rack system.  As the system is loaded rear to front, it must it be unloaded front to rear.

Drive-In systems reduce the number of aisles required in a warehouse.  It is frequently used in cold storage applications, where the cost of (refrigerated) volume is at its highest and requires the most return on investment (more density).

Drive-In is limited by the warehouse management system and its ability to slot pallet locations.  Utilization is typically low due to honeycombing and drive-in rack is subject to more abuse due to the constant movement of fork lifts in and out of the rack.  It is also a system that can require a pallet to be handled multiple times before shipping.  If multiple SKU’s or manufacture dates are stored in a bay, handling product multiple times can lead to product damage.

A large warehouse with drive in racking.
A view of drive-in racking from a warehouse aisle.

Structural drive-in is built for high-contact lift environments, making it a strong choice for beverage and grocery reserve lanes and high-cycle food DCs. Structural rack’s impact tolerance and repairability help protect uptime.

Structural Drive-In:

A large warehouse with tall metal shelving units stacked with pallets of goods, in drive-in racking.
Warehouse storage shelves filled with stacked boxes wrapped in plastic, layered within drive-in racking.

Roll form drive-in can be a cost-effective route to density when impacts are minimized and you want lighter components. Given roll form rack’s thinner-gauge construction, protect the system with entry guarding, upright protection, and strict lift procedures.

Roll Form Drive-In:

Empty metal shelving drive-in racking.
Long warehouse aisle between drive-in racking.

Drive-In Advantages

  • High-storage density for certain product mixes

  • Low capital investment vs. other high density options

  • Very efficient storage (ability to store pallets back-to-back without aisles)

Drive-In Limitations

  • Inflexible, does not allow for SKU increase

  • Possible low storage utilization (typically 50% of positions used)

  • Low productivity (30% slower than alternative systems)

  • Requires standardized pallets

  • Risk of rack damage by fork trucks

  • LIFO – Last In First Out

  • Difficult to rotate time-sensitive products

Industry Applications

Technical drawing of drive-in warehouse pallet racking.
A brochure page describing drive-in rack systems including the advantages and disadvantages.

DRIVE-IN

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