Pallet storage methods

Most companies store their products in pallets at their warehouses. Depending on the necessities and the storage limitations, there are several pallet storage methods that can be used by the warehouse staff to efficiently storage the merchandise. In today´s post we will examine some of the most common pallet storage systems.

Block Stacking: The method of block stacking involves stacking boxes or units one on top of the other, and store them on the warehouse floor in lines of blocks. This is one of the most cost effective methods since it doesn´t require to use racks.

The pallets can be stacked to a specific height based on three conditions: 


-          The weight of the items placed on the pallets.

-          The height of the warehouse.

-          The pallet conditions

The pallets will need to be retrieved from the pile in a last in, first out manner, LIFO (not to be confused with the FIFO manner, which means first in, first out), therefore when stacking the boxes it has to be taken into account which pallet will be needed first to avoid leaving unusable empty spaces (this is referred to as a honeycombing effect) that can´t be refilled until the whole rack has been emptied.

This method is more useful for small and medium size warehouses that want to keep their expenses controlled.  

Stacking Frames: Stacking frames method allows for pallets to be store very high and it´s particularly useful when pallets are not stackable. The frames are made from decks and post and can be moved easily through the warehouse when needed.

This system is most used for those warehouses that need some extra space during busy periods. With stacking frames the issue of honeycombing is similar to block stocking.

Single-Deep Pallet Rack: Single-deep pallet racking provides access to each pallet stored in the rack, this method ends the honeycombing problem as whenever a pallet is taken out, a new one can be placed where the original was. This type of racking allows various heights depending on the needs of the warehouse and the forklift’s abilities.

There are several reason that make this method more efficient than others. Honeycombing issues are not a problem anymore as we said and space is available as soon as a pallet is removed. On the other hand, this method requires more space therefore warehouses with limited space are advice to choose a different pallet storage method.

Double Deep Rack: This method is similar to the single deep pallet rack differing in the double-deep rack being able to store pallets two deep. The double deep rack incorporates two single racks that are placed together, leading to a reduction of the number of aisles required, nonetheless this type of racking is susceptible to honeycombing and it might not be as efficient as the single deep racking.

Finally, double deep racking will require the business to invest in a double forklift to remove or place the pallets.

Drive-In Rack: This method offers from five to ten pallet spaces much alike the double deep rack. This type of method is similar to the block stacking because the last in and first out principle, LIFO, is used when retrieving pallets. The biggest problem of the drive in rack method is that it provides limited space for the forklift to place and remove stock resulting in increases of the time needed to maneuver the stock.

Pallet Flow Rack: This method is maybe the most expensive but I might be worth it as in some cases it´s also the most efficient. The pallet flow rack method makes it possible for a pallet to be moved from one end of the rack to the other end on a conveyor. The pallets are removed using the first in, first out method (FIFO). Once a pallet has been removed from its place, another pallet can be placed on the spot left

Push Back Rack: This method uses a rail guided carrier to push the pallets further back into the storage area. When a pallet is placed it pushes the other pallet loads back. When a pallet load is taken off, the next pallet is moved into that load’s position. This system is a LIFO solution and might not be suitable for those warehouses requiring FIFO. 

Depending on the particular need of a warehouse, choosing the best and most efficient pallet storage method can lead to more space, more time and more money saved.