Did you know that a warehouse equipped with the right pallet racking system can move up to one-third more pallets per hour than a facility that relies on floor stacking alone? This jump in efficiency doesn’t demand extra labour or square footage, just smarter use of vertical space and traffic flow.
For businesses intent on remaining competitive, selecting the best pallet racking solution is more than a logistical decision; it directly influences throughput, safety and profitability. Whether you manage a bustling distribution centre or a compact storeroom, the world of industrial pallet racking offers tailored options that align with SKU profiles, stock rotation strategies and growth plans. Understanding those options now will help you avoid costly reconfigurations later and keep operations agile as customer demands evolve.
Exploring the Different Types of Pallet Racking Systems
The market offers a diverse range of industrial pallet racking options, each engineered to solve specific storage challenges. From maximising pallet selectivity to achieving the highest possible density, these systems differ in how they balance accessibility, capacity and capital cost. Below is a closer look at four of the most widely adopted solutions.
Selective Pallet Racking
Selective racking remains the industry standard because it gives forklifts direct access to every pallet. Uprights and beams are configured in single-deep rows that can be adjusted to suit changing load heights, making the system remarkably flexible.
Key advantages include:
- 100% pallet selectivity, ideal for high SKU counts and fast-moving inventory
- Compatibility with virtually any forklift type, reducing equipment investment
- Ease of inspection and maintenance, supporting stringent safety audits
Double Deep Pallet Racking
Double deep pallet racking stores pallets two positions deep, effectively doubling capacity within the same run of racking. Special reach trucks retrieve the rear pallet, closing the slight gap in selectivity compared with selective racking.
The system offers:
- Up to 30% higher storage density while retaining reasonable access
- Lower aisle requirements, freeing space for additional pallet positions
- Cost-effective expansion for facilities handling medium-volume SKUs of the same product
Drive-In Pallet Racking
Drive-in racking allows forklifts to travel directly into lanes formed by continuous rails, stacking pallets as many as ten deep. Working on the FILO principle, it cuts aisles dramatically and delivers very high cubic utilisation of the warehouse.
Stand-out features include:
- Up to 500% more storage capacity than selective systems, making every cubic metre count
- Simplified lane management for bulk loads with low SKU variety
- Reduced need for additional uprights, lowering structural costs
Push Back Pallet Racking
Push back pallet racking positions pallets on wheeled carts or rails set on a slight incline. When a new pallet is placed, it “pushes back” the previous load, allowing up to five pallets deep per lane while enabling last-in, first-out retrieval.
Benefits you can expect:
- High density without the need to drive into the rack structure, improving safety
- Faster loading and unloading compared with drive-in lanes
- Excellent visibility of front-facing pallets, simplifying cycle counts
FIFO vs LIFO: Inventory Strategy as a Design Driver
First-In, First-Out (FIFO) ensures the earliest pallet received is the first pallet shipped. It is crucial for perishable goods, date-sensitive SKUs and any environment governed by strict traceability.
Racking systems that naturally support FIFO include:
- Selective racking offering direct pick access to every pallet
- Pallet live racking which uses gravity rollers to feed stock forward automatically
- Automated storage and retrieval systems (AS/RS) coordinating robotic cranes for perfect date rotation
Last-In, First-Out (LIFO) sends the most recently stored pallet out first, suiting durable goods, bulk materials and staging zones.
Systems that favour LIFO include:
- Push back pallet racking where the latest pallet sits at the pick face ready for rapid retrieval
- Drive-in racking ideal when high density outweighs the need for full selectivity
- Double deep pallet racking providing partial selectivity while still operating on a LIFO basis for the rear pallet
Key Considerations When Choosing a Pallet Racking System
Selecting the right racking isn’t just about matching a product list to a storage style; it’s about orchestrating space, workflow and future growth into a single cohesive plan.
First, evaluate how every aisle, beam and upright will influence space utilisation. Start with a detailed warehouse layout that accounts for column spacing, door positions and mezzanines. Advanced modelling software can render multiple scenarios, showing how selective racks accommodate cross-docking, how double deep pallet racking adds capacity in a congested corner or how a push back lane along a perimeter wall can eliminate wasted dead zones. By overlaying forklift travel paths and pick rates, you’ll see where tighter aisles or deeper storage will speed throughput rather than hinder it.
Equally vital is scalability. Today’s SKU mix rarely stays static, so the system you install must adapt as product lines, order profiles and automation technologies evolve. Look for industrial pallet racking that supports bolt-on extensions, adjustable beam levels and easy integration with carton flow or shuttle systems. Planning for mezzanine legs, conveyor interfaces and automated guided vehicles now can save significant retrofit costs later. Businesses that embraced flexible rack designs a decade ago have since shifted from per-pallet to per-case fulfilment without ripping out core infrastructure, proof that adaptability is an investment, not an expense.
Safety and compliance sit alongside capacity on the priority list. In Australia, pallet racking must adhere to AS 4084 – 2012. Ensure your supplier provides engineering certification, routine audit services and components such as lock-in pins and column guards. Beyond preventing costly incidents, a documented compliance programme supports insurance requirements and reinforces your commitment to worker well-being.
Finding the Right Pallet Racking Solution for Your Business
Choosing between selective, double deep pallet racking, drive-in or push back pallet racking isn’t merely an operational detail; it’s a strategic investment that safeguards product integrity, streamlines workflows and leaves room for future expansion. When the racking solution aligns with SKU velocity, inventory method and available footprint, warehouses consistently report faster pick rates, reduced damage and measurably lower handling costs. In short, the right system turns shelving into a silent productivity partner. Contact Elbowroom for a free consultation to find the perfect pallet racking solution for your business.
