Struggling with limited warehouse space? A poor storage layout creates unused space and costs more to operate. Having improper storage methods hurts your ability to track inventory and slows down your operations. Drive-In Racking provides a transformational answer to storage issues. High-density storage systems help you optimize space usage while decreasing the number of aisles needed to operate efficiently. Traditional pallet racks handle fewer products yet need more space. Drive-In Racking optimizes warehouse operations in both bulk storage and cold storage environments. Let’s explore how this storage system works along with its advantages and practical uses. Let’s dive in!

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What is Drive-In Racking?

Drive-In Racking lets you save warehouse space by building fewer storage aisles. The system enables forklifts to go into storage lanes to access pallets which makes it the perfect solution for bulk storage. Its unique Last-In First-Out functionality matches well with businesses in food processing, manufacturing, and cold storage sectors. This storage solution maximizes space usage to store large amounts of identical items at low operating expenses. When space optimization stands as your main concern Drive-In Racking delivers the perfect answer.

How Does the Drive-In Racking System Work?

The Drive-In Racking system improves warehouse space utilization by creating parallel aisles for forklift operations. You steer the forklift into the storage area to add or remove pallets. Items are placed on support rails for storage which reduces the number of aisles needed. Set the pallet in place on the support rails when you lift it up above the rail system. Unloading follows a reverse order. This system handles storage with both LIFO and FIFO techniques and performs best when space is limited.

Types of Drive-In Racking Systems

There are two primary types of Drive-In Racking – Drive-In Pallet Racking and Drive-Through Pallet Racking. Each storage solution has its own designated purpose.

Drive-In Pallet Racking (LIFO – Last-In, First-Out)

A single transportation path controls this storage method. You place pallets at the entry point first and the final pallet you put in becomes the first one you take out. This storage system handles large quantities of slow-moving goods perfectly. This space-saving storage solution reduces aisle needs and optimizes available room because you rarely rotate your inventory.

Drive-Through Pallet Racking (FIFO – First-In, First-Out)

The arrangement includes two different points for putting items in and taking them out. When items enter the warehouse they enter the rack in sequence and are the initial items to leave. Use this system to store perishable goods that need fast handling. When you handle a large number of fast-moving products this system helps keep inventory moving without delays.

Advantages of Drive-In Racking for Pallet Storage

Maximizes Warehouse Space

You can fill 80% of your space using Drive-In Racking technology. Drive-In Racking enables higher pallet placement density which benefits warehouses that do not have a lot of space.

Cost-Effective Solution

Drive-In Racking demands low upkeep which decreases future financial responsibilities. The basic design structure lets you save money while achieving high storage density through easy setup.

Ideal for Bulk Storage

Drive-In Racking works best when you store many identical products together. Its ability to organize uniform products effectively makes it widely used across food factories and beverage plants.

Enhanced Stock Control

Perpendicular lanes help you arrange your palletized goods efficiently. Our system helps prevent stock mishandling and strengthens order correctness so you can manage your stock better and work more effectively.

Reduction in Aisle Space

Warehouses must provide spacious paths for trucks to enter and leave traditional racks through aisles. Drive-In Racking enables you to replace empty corridor space with more usable storage zones.

Scalability & Modularity

You can grow or adapt your storage setup as your requirements evolve. Its easy-to-adapt design lets you change how your warehouse system works when your business grows.

Cold Storage Efficiency

Drive-In Racking works effectively in storage facilities that need to keep products chilled or frozen. The storage system’s dense design keeps temperature steady while lowering energy use and space needs for cooling warehouses.

Disadvantages of Drive-In Racking for Pallet Storage

Difficult Inventory Management

You need to shift pallets around to locate the desired one. Operations that require fast stock handling face greater difficulties due to this system design.

Not Ideal for High-Mix Storage

Drive-in racking performs best when you store numerous identical items in bulk. When managing many different products this warehouse system slows down your operations and restricts your storage options.

Increased Risk of Stock Obsolescence

Products that age in storage can take long periods to remain there. High turnover businesses often face damaged and expired products from continuous storage of inventory in this system.

Risk of Forklift Damage

Forklifts running into racking structures becomes more likely damaged because of the tight spaces. Frequent contact between forklifts and storage equipment reduces safety through more repair work.

Slower Loading and Unloading

Forklifts require more time to properly position and retrieve pallets compared to using selective racking. Frequent forklift movements with drive-in racks reduce the speed of warehouse operations.

Frequent Repairs Required

Frequent forklift usage causes more damage to drive-in racking systems. Regular maintenance involves changing worn components to keep the system safe.

When Should You Choose Drive-In Racking?

Warehouses with Limited Space

Businesses with small warehouse space and expensive storage can use Drive-In Racking systems to solve their space challenges. You can fit more pallets in the same space because this system removes unusable walkways. The optimized storage layout helps you lower your building costs and use available space better.

Storage of Large Identical Products

Your warehouse can benefit from Drive-In Racking when you have large amounts of single product items that move slowly through storage. This storage method works best for uniform goods because it manages LIFO and FIFO inventory control methods.

Storage of Perishable and Non-Perishable Goods

This storage space solution helps manage large product quantities without affecting stock turnover rates. Foods, drinks, and pharmaceuticals benefit from the Drive-Through system because it keeps perishable items in proper rotation from first to last.

Facilities Concerning Space Requirements

Drive-In Racking delivers affordable storage for items that do not require immediate access to every pallet. This system helps you keep stock neat and saves space in both upward and forward directions.

Cold Storage and Freezing Chambers

Cold storage operations achieve better results through Drive-In Racking systems. By storing inventory closely together the system helps distribute temperatures well while lowering power expenses. Your storage operations stay effective with this system and you save money from operational costs without losing product quality.

Main Components and Accessories of Drive-In Racking

Drive-In Racking systems use strong safety and structural components to keep operations running efficiently and safely. Learning about these parts makes it easier to choose the right storage solution.

Main Components of Drive-In Racking Systems

Upper Longitudinal Beam

At the top of every racking system the upper longitudinal beam connects frames crosswise to maintain its stability. It keeps everything standing straight to reduce wobbling and support heavier weights. All compact aisle racking systems engage with the upper longitudinal beam to create a strong and straight framework.

Horizontal Brace

The horizontal brace strengthens the entire racking system above. The sturdy metal element strengthens stability as it counteracts sway to maintain the structure in place. The horizontal brace ensures high-density storage systems stay stable and level.

Frame

The frame creates the main structure of our Drive-In racking system. This system includes both vertical uprights with diagonal braces supplemented by baseplates and attachment mechanisms. This foundation element keeps the racking system stable by handling the weight of loaded pallets and retaining its proper setup.

Upright

The upright works as the basic member that holds up the entire frame design. The galvanized steel uprights come in several sizes and lengths to fit various warehouse setups. It keeps pallets stable during system loading operations.

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Pallet Beam or Support Rail

The pallet beam and support rail system directly takes weight of stored goods. The metal frames run parallel to the vertical uprights to create levels where storage pallets are placed. Brackets securely attach the support rails to maintain correct weight distribution and shield them from bending or breaking.

Bracket

A bracket securely joins support rails or pallet beams to uprights. Although unrelated to pallet loading it provides stability by spreading out the weight evenly. Brackets placed correctly shield the system from misalignment and weak spots.

Accessories for Safety and Efficiency

Forklift Guide Rail

Guide rails help forklifts move easily between warehouse racks. The steel guide rail at floor level helps forklifts stay on course and prevents crashes during operations.

Frame and Upright Protection

Protecting the lift truck frame and upright supports is necessary to avoid equipment damage. Protect your system from damage by installing frame protectors and upright impact absorbers.

Welded Baseplate

The welded baseplate strengthens frames to handle more weight and taller storage requirements A strengthened base foundation keeps the system from tipping over and makes it last longer.

Pallet Guidance

Pallet guidance helps forklift operators put unit loads where they should go. The system guards against loading accidents that could harm the frame’s structure.

Pallet Backstop

A pallet backstop protects products during handling by creating a safety zone at the end of the aisle. The device keeps pallets stable during movement to avoid product damage and workplace safety threats.

Manufacturing Excellence in Drive-In Racking Systems – M Racking

5-Year Quality Guarantee

Your warehouse dependability increases when M Racking offers a 5-year quality assurance plan. The systems stand up against heavy loads and repeated use because they are constructed to last.

ISO & Safety Certifications

Compliance matters. You can trust M Racking because it follows international ISO safety standards that demonstrate product safety and workplace protection. Certified systems lower workplace risks and create more practical workflows.

Traceability System

Every component is trackable. Our traceability system tracks every part in the system to simplify maintenance and part replacement work. Our system shows you exactly where each part comes from and its level of quality.

Automated Manufacturing

Precision is key. Advanced manufacturing systems produce reliable products at precise levels through their automated processes. An engineering team builds an optimized racking system that performs well under heavy loads.

Advanced R&D & Testing

Innovation drives performance. M Racking puts money into research and product quality testing alongside constant system enhancements. The latest designs, advanced safety features, and better storage methods benefit you.

Conclusion

Drive-In Racking helps warehouses reach their space and efficiency goals effectively. This storage solution provides great space efficiency and handles bulk products efficiently. Cold storage operations and manufacturing plants use Drive-In Racking due to its space-saving design. It gives companies better control over their stock while delivering financial and logistical benefits. A superior racking system selection delivers long-term usage and operational reliability. Use this system in your warehouse setup to get more done faster through an efficient storage method.

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The 10 Most Common Types of Pallet Racking System

Pallet racking systems pervade the logistics landscape. Scattered across the country in distribution centres, sheds and stores, racking fixtures of all shapes and sizes store goods for our nation. But, if you look carefully you will see that not all racking systems are the same.

For those in the industry this is well known, but for the novice, it’s not so easy to spot the differences, let alone understand why you would use one type of racking versus another.

To help understand what types of racking are available, when to use them, and when to avoid them, I briefly list each type below with an explanation, estimate of utilisation and an indicative budget price to purchase (exclusive of GST). There is a sketch of each as well to assist in seeing how they operate.

There are additional types of storage racking and order picking equipment – also, the author wishes to thank racking suppliers Schaefer and APC who advised budget prices for each racking more.

1. Selective

The selective pallet rack is a widely used and cost-effective storage solution for warehouses, providing direct access to all loads stored and ensuring maximum efficiency.

It offers various configurations, options for heights and beam sizes, and has been popular since the s due to its affordability and flexibility in meeting different storage needs.

Features

• Clear Aisles of 3 to 3.4m for reach trucks or 3.5 to 4.5m for counter balanced fork lifts
• Supports First in First Out (FIFO)
• Most common mode of racking
• Unfettered access to any pallet
• Allows order picking at lower levels
• Storage Utilisation: 90%
• e. for every 100 pallet places available, you can fill 90

When do you use it?

• Where you have a relatively low number of pallets per SKU
• When you want totally free access to any pallet, any time
• When you need to pick from pallets at lower levels

Of course, specific circumstances in your warehouse operation, which might not correspond directly with the conditions mentioned above, might mean that selective racking is an ideal solution for your business.

When not to use it?

• When you have a high number of pallets per SKU and you are constrained for space
• When you need to pick from more pallets than the lower level pick face will allow

Budget Price: $46-60 per pallet

On a side note, our inventory management services include the provision of advice and guidance about storage solutions, so please feel free to get in touch and ask about selective racking as an option for your warehouse.

We are vendor-agnostic and we don’t sell storage equipment, so you are assured that our guidance will be totally objective, reflecting what we believe to be the best solution for your circumstances.

2. Push Back Racking

Push back racking is a popular solution in many warehouses because it saves space and increases efficiency. What this does is it allows you to store multiple pallets on one rack, and then access them from the front. It’s perfect for where space is limited and quick access to stock is key.

Push back pallet racking is a high density storage system that uses inclined rails and free rolling carts to store and retrieve pallets. With this racking system, you can store up to 6 pallets deep and access from the front, which makes it ideal for LIFO (Last In First Out) inventory. The key benefits of push back pallet racking are space and density, especially in warehouses and cold stores.

Features

• Clear aisles of 3 to 3.4m
• First in last out (FILO) for each slot
• Can be three or four pallets deep, but commonly only two pallets deep
• Pallets are pushed back from aisle by fork lift trucks
• Pallets are placed on low friction carts
• Used for full pallet storage only
• Forklift drivers need to be careful when loading in an out to avoid pallet damage
• Utilisation: 85-90%

When do you use it?

• When you have more pallets per SKU and want to gain greater storage density
• When order picking is not required from pallets within push back racking

When not to use it?

• When you need to perform order picking from pallets
• When pallets are accessed frequently for picking and are then put away again
• Where pallet to pallet contact is can cause damage to stock

Budget Price: $275-295 per pallet

3. Double Deep Racking

Whilst selective racking is popular for its versatility and ease of access to individual pallets, another effective type is double deep pallet racking, which optimizes storage capacity by utilizing two rows for pallet storage. This system is particularly effective in LIFO inventory systems and can help to minimise aisle space, which allows for more efficient use of warehouse floor area, although it requires forklifts with longer tynes for access.

Features

• Clear aisle of 3.0 to 3.4m
• FILO for each slot
• Pallets at lower levels must be on beams, and guide rails are used at upper levels
• Needs a fork lift truck with extendable reach and camera to assist the operator
• Generally used for placing two pallets of the same SKU in each double deep slot
• Can be serviced by reach and counterbalanced fork lift tricks and order picking machines
• Storage Utilisation: 85-90%

 When do you use it?

• When you have more pallets per SKU
• When greater storage density is required

When not to use it?

• When you need to perform order picking from pallets
• When pallets are accessed frequently for picking and are then put away again
• When you have lots of SKUs with single pallets in stock

Budget Price: $55-65 per pallet

4. Pallet Live Storage

Pallet Live Storage also known as pallet flow racking is a dynamic storage solution that uses gravity to move pallets from the loading to the unloading point. Great for warehouses that need high density storage and fast inventory turnover. By using inclined gravity roll tracks pallets move to the front of the rack as items are removed, First-In, First-Out (FIFO) inventory management. This maximises storage space and reduces time and effort to access stored goods. Ideal for high volume operations Pallet Live Storage is the go to solution for businesses looking to optimise their warehouse racking and increase storage capacity.

Features

• Clear aisle of 3.0 to 3.4m
• FIFO for each lane
• Pallets are placed on gravity roll tracks and move from entry to exit via gravitational pull
• High use of cube
• One lane per SKU
• Separate load in and load out aisles
• Full pallets only
• Utilisation: 85-90

When do you use it?

• When you need FIFO Operation and stock is moving at relatively fast rate
• When you have a high number of pallets per SKU
• Where you need high space utilisation

When not to use it?

• When you have few pallets per SKU
• When you need to perform order picking
• When you cannot tolerate pallets encountering others due to line pressure
• When you cannot tolerate occasional snags caused by pallets stalling on the roll tracks

Budget Price: $400-420 per pallet

5. Drive in Racking

Drive in racking is a space saving solution that allows forklifts to drive into the storage lanes. It’s great for storing large quantities of the same item and industries with high stock turnover. One of the good things about drive in racking is that it reduces the need for multiple aisles so increases storage density and space utilisation.

Features:

• Clear Aisles of 3 to 3.4m for reach trucks or 3.5 to 4.5m for counter balanced fork lifts
• FILO for each bay
• The fork lift drives down the lane of each racking bay to deposit or pick up pallets
• Drive in racking emulates the operation of block stacking, but with the racking there is reduced damage to pallets and stacking can be higher
• Can be up to 10 or 12 pallets deep and up 6 or 7 pallets high
• Utilisation: 50-60%

When do you use it?

• When FILO is not a problem
• When you do not wish to mix SKUs within each bay/lane of drive in racking
• When high density storage is required, (but be careful of the honeycomb effect) which reduces utilisation
• When staging of received or picked goods is required in a high-density format

When not to use it?

• Where order picking is required from pallets
• When you are planning for greater than 60% space utilisation

Budget Price: $165-180 per pallet

6. Narrow Aisle Racking (Turret Truck Operation)

Narrow aisle racking is a favourite for warehouses that want to make the most of their space and still be able to access everything. This type of racking allows for more floor space by reducing the aisle width between racks. It’s perfect for high turnover warehouses as you can get to your stock quicker and easier.

Narrow aisle turret trucks and articulated trucks are both good for warehouse operations, but they work differently to each other. A turret truck has a rotating mast and fork assembly that can turn 180 degrees while the body stays in the aisle.

These trucks are great in very straight, narrow aisles where they only need to move forward and backward and they can lift higher, often over 50 feet. However, they need excellent floor conditions and precise racking installations to operate safely.

Features

• Clear aisle of 1.8 to 2.2m
• Emulates characteristics of selective racking
• Turret trucks retrieve/put away pallets from pick and deposit (P&D) stations at the end of each bay of racking
• Turret trucks require wire or mechanical guidance down the length of each aisle
• A separate forklift delivers and picks up pallets to and from the P&D stations
• Order picking machines may pick from pallets, but not at the same time as turret trucks
• Only one machine in an aisle at a time
• Utilisation: 90%

When do you use it?

• When you have a high SKUs with relatively small quantities per SKU
• Where you want good space utilisation
• When you have large amounts of goods moving and out
• When you want to improve the storage density within your warehouse

When not to use it?

• When you can’t afford to have two machines operating
• When you have limited budget
• When you have a high movement velocity and need two machines working in the same aisle at the same time

Budget Price: $50-60 per pallet (not including wire or angle guidance system)

7. Narrow Aisle Racking (Articulated Truck)

Articulated trucks give you an alternative method of handling narrow aisle operations, primarily because they have a pivoting midsection. This gives them that ability to transition from forward travel to sideways stacking without taking up more aisle space than a conventional forklift.

Articulated trucks are particularly good in mixed use facilities where they can move beyond the racking areas. Whilst they don’t quite reach the same heights as turret trucks, they can handle imperfect floors and more flexibility.

Features

• Clear aisle of 1.8 to 2.2m
• Emulates characteristics of selective racking
• Articulated reach trucks can move from truck unloading to rack without the need for (P&D) stations or guidance
• Order picking machines may pick from pallets, but not at the same time as turret trucks
• Only one machine in an aisle at a time
• Utilisation 90%

When do you use it?

• When you have a high SKUs with relatively small quantities per SKU
• Where you want good space utilisation
• When you have large amounts of goods moving and out
• When you want to improve the storage density within your warehouse

When not to use it?

• When you want one machine servicing the racking
• When you have a high movement velocity and need two machines working in the same aisle at the same time

Budget Price: $50-60 per pallet (no guidance required)

8. Mobile Racking

Mobile racking is a solid choice if you need a space saving storage solution for warehouses. By putting racking on wheels, aisles can be reduced and accessed as needed, which helps to increase your warehouse capacity. This is perfect for facilities with limited space and high storage needs.

Features

• Clear aisle of 3 to 3.4m
• Mobile bases with wheels support selective racking
• Operates like a powered compactus
• Mobile racks move to allow access to pallets
• One aisle opens at a time
• Ideal for high density storage, with maximum selectivity
• Often used in cool and cold stores
• Utilisation: 90%

When do you use it?

• Use when there is a high amount of storage, but with modest movement of pallets
• When you are handling full pallets only
• When building and operating expenses are high e.g. cool and cold stores

When not to use it?

• When space is not at a premium
• When you need to perform lots of carton picking from pallets
• When you need operate in more than one aisle at a time

Mobile racking is an expensive solution, but a highly effective one in some warehousing scenarios. If it’s something you are considering for your company, our inventory management consultants can help you with an unbiased cost-benefit analysis, enabling you to make the right decision with total confidence.

Budget Price: $700-800 per pallet

9. Satellite Racking (Deep Lane Pallet Racking)

Satellite racking systems can help to transform the way your warehouse stores products, and by using automated shuttles these systems can increase storage density and retrieval times. It’s a great option for businesses with high turnover and large volumes of stock.

Features

• Clear aisle of 3 to 3.4m
• High density storage system, which utilises a mobile shuttle (remotely controlled) to move the pallets through the racking
• Can be 10 to 40 pallets long per lane
• The shuttles are placed and retrieved from the racking by fork lift trucks
• Can operate in FIFO and FILO modes
• Often used as an alternative to drive in racking, because the utilisation is much higher
• Utilisation: 90 to 95%

When do you use it?

• Used when there is a high volume of products moving through of each SKUs
• One SKU per lane
• Used to overcome the poor space utilisation of drive in racking

When not to use it?

• When you need to pick from the pallets

Budget Price: $185-250 per pallet, $50,000 per shuttle

10. High Rise Racking (Automated Storage and Retrieval Systems)

High Rise Racking systems, also known as Automated Storage and Retrieval Systems (ASRS), are a more advanced pallet racking solution to increase warehouse storage capacity and efficiency. They use automated cranes to store and retrieve pallets, so you can store more in your warehouse whilst making a much smaller footprint.

The high rise design lets you make the most of your vertical space, and it makes it perfect for sites with limited land. ASRS can store one or multiple pallets deep, so you have flexibility in your storage layout. While the initial cost is higher than standard, the long term benefits in efficiency and space usage makes it worth considering for high volume warehouses.

Features

• Clear aisle of 1.8 to 2m
• High density storage system usually serviced by automated cranes. Can be single or multiple pallets deep, open or closed face
• Needs dedicated building, rack clad or free standing
• Utilisation: 90 to 95%

When do you use it?

• Use when land space is limited, and/or if there is a high volume of products moving in and out of the system
• The number of pallets per SKU becomes irrelevant as the system is automatic and all pallets are accessible

When not to use it?

• When budget is limited
• You do not need to pick from pallets (If you do these can be done elsewhere in the distribution centre)

Budge Price: $350-400 per pallet. But don’t forget the price of the building $950-/sqm.

Rack Up the Savings with Improved Inventory Management

Improving inventory control and management is one of the fastest routes to end-to-end supply chain cost reduction, and your choice of warehouse storage systems is a crucial element in the success of your IM strategy.

Of course, there is a lot more to effective inventory management than the way your store your pallets, and at Logistics Bureau, we offer a comprehensive portfolio of IM services to help you with all aspects of the challenge.

From diagnostics to direct intervention, our consultants can provide you with the impartial support that equipment, software, and solutions vendors have no incentive to offer. In return for our fees, we deliver genuine value through recommendations that are right for your business, not for any partners on the supply side.

We even offer an initial no-obligation, inventory management consultation free of charge, during which we’ll review your storage or other IM-related situation, identify the key issues to resolve, and help you develop an action plan to address them.

If you want to learn more, please visit our website pallet racking china.

Best Regards,
Rob O’Byrne
: [ protected]
: +61 417 417 307