Pallet racking is the most essential element of any modern warehouse or logistics facility. It is a material handling storage system designed to organize goods stored on pallets in horizontal rows across multiple vertical levels, converting vast amounts of empty vertical space into usable inventory locations.
In short, pallet racking is the steel backbone that allows businesses to achieve storage density and inventory management in their facility.
1. How Pallet Racking Works
Pallet racking systems operate on a simple principle but require precision engineering:
- Structure: The system is built using two primary components: Upright Frames (the vertical columns that bear the load) and Beams (the horizontal supports that connect the frames and create the shelf levels for the pallets).
- Loading: Forklift trucks are required to lift and place loaded pallets onto the horizontal beams. The design allows the forklift operator to easily access and retrieve the unit loads.
- Safety & Compliance: Every racking system is rated for a specific Safe Working Load (SWL), which is the maximum weight the beams and the overall bay can safely hold.6 Adherence to standards like AS 4084 is crucial for structural integrity and operational safety.
2. Key Benefits of Using Pallet Racking
Implementing a dedicated pallet racking system offers immediate operational advantages:
- Space Optimisation: The primary benefit. Racking utilises a facility’s vertical height, significantly increasing storage capacity without requiring additional floor space.
- Improved Inventory Management: By organizing products into distinct, identifiable bays, racking simplifies tracking, cycle counting, and inventory rotation (FIFO/LIFO).
- Enhanced Safety: When installed correctly, racking provides a safe, secure, and structured environment for storing heavy goods, reducing product damage and protecting workers from falling loads.
- Versatility: Most racking is modular, allowing beam heights to be adjusted to accommodate changing pallet sizes and inventory requirements over time.
3. Overview of Pallet Racking Types
The choice of racking system dictates the balance between selectivity (direct access to every pallet) and density (using space efficiently).
| Racking Type | Selectivity (Access) | Storage Density | Best For |
| Selective Racking | 100% (Direct access to every pallet) | Low | High SKU count, fast-moving items, general warehousing. |
| Double Deep Racking | ~50% (Two pallets deep) | Medium | Increased storage with a reach forklift; medium SKU count. |
| Drive-In Racking | Low (LIFO: Last-In, First-Out) | Very High | Large volumes of identical product, cold storage, low SKU count. |
| Pallet Flow Racking | High (FIFO: First-In, First-Out) | Very High | Perishable goods, high-volume shipping, time-sensitive inventory. |
| Push-Back Racking | Medium (LIFO) | Very High | Medium SKU variety requiring denser storage than selective. |
| Cantilever Racking | N/A | Specialised | Long, awkwardly shaped materials like timber, steel, or piping. |
Pallet racking is the indispensable foundation for efficient logistics. By selecting the appropriate racking type that matches your inventory flow (FIFO vs. LIFO) and product volume, businesses can fundamentally transform their operations, maximizing available space and controlling costs.
