Warehouses and distribution centres face growing pressure to optimise space, increase efficiency, and handle larger volumes of inventory. Choosing the right storage system is essential for achieving these goals. A double racking system is one of the solutions available, offering greater density than traditional selective pallet racking. To determine if it is the right choice, it is important to compare how it performs against other pallet racking options in terms of storage capacity, accessibility, cost, and suitability for different operations.
What Is a Double Racking System
A double racking system, often referred to as double deep pallet racking, stores pallets two positions deep instead of one. This configuration reduces the number of aisles required, which increases storage density. Forklifts with extendable forks or reach trucks are typically required to access the rear pallets.
Key Features
- Stores pallets two deep, maximising density
- Reduces aisle requirements, optimising floor space
- Requires specialised equipment for handling
- Works on a first-in, last-out storage principle
Advantages of a Double Racking System
Increased Storage Density
By storing pallets two deep, warehouses can achieve up to 30 percent more capacity compared to selective racking. This makes it a strong choice for space-constrained facilities.
Cost-Effective Expansion
Instead of expanding buildings or investing in new facilities, businesses can increase capacity by upgrading to a double racking system within their current footprint.
Suitable for Bulk Storage
The system is ideal for storing large quantities of similar products, particularly medium to low turnover items.
Improved Organisation and Safety
Goods are stored in structured rows, keeping floors clear of clutter and supporting safer operations.
Double Racking System vs. Other Pallet Racking Options
Selective Pallet Racking
Selective racking provides direct access to every pallet. While it is the most flexible system for fast-moving inventory, it offers lower storage density compared to a double racking system. Businesses must decide whether accessibility or capacity is the higher priority.
Drive-In Racking
Drive-in racking allows forklifts to move directly into the structure to place or retrieve pallets. This system provides higher density than double racking but limits selectivity, making it best for storing large volumes of the same product. Double racking strikes a balance between density and access.
Push-Back Racking
Push-back racking uses a sliding mechanism to store multiple pallets deep. Like double racking, it increases density, but it is more suitable for operations where pallets are accessed in a first-in, last-out sequence. Double racking is often simpler and less costly to install.
Pallet Flow Racking
Pallet flow systems use gravity rollers to move pallets forward automatically, working on a first-in, first-out basis. While they support excellent stock rotation, they are more complex and expensive compared to a double racking system.
When to Choose a Double Racking System
A double racking system is most effective in warehouses that need to maximise capacity without compromising accessibility entirely. It is particularly suitable for:
- Warehouses with medium-turnover products
- Facilities with limited floor space
- Businesses storing bulk or homogeneous stock
- Operations that can work with a first-in, last-out system
Considerations Before Installation
Equipment Compatibility
Warehouses must have or invest in forklifts with extendable forks or reach trucks to operate a double racking system effectively.
Inventory Management
Since direct access to rear pallets is limited, this system is not ideal for perishable goods or items requiring strict first-in, first-out rotation.
Training and Safety
Operators need training to handle equipment safely and efficiently. Regular inspections and maintenance also ensure the stability of the racking structure.
The Future of Double Racking Systems
As warehouse automation grows, double racking systems are expected to integrate with smart forklifts and warehouse management software. This will help businesses achieve greater accuracy, speed, and safety in operations. Its balance of storage density and accessibility ensures that double racking will remain a popular choice for many industries.
Conclusion
A double racking system provides a cost-effective way to maximise storage capacity while still allowing reasonable access to stored goods. Compared to other pallet racking options, it offers a balance between the high selectivity of selective racking and the high density of systems like drive-in or pallet flow. With the right planning, equipment, and maintenance, it can significantly improve warehouse efficiency. For organisations seeking tailored storage solutions, Dalvie Systems offers expert support in designing and installing double racking systems that meet specific operational needs.
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