Choosing the right pallet racking system can make or break your warehouse efficiency. Whether you’re setting up a new facility or upgrading your existing storage racking, getting it right means better organisation, improved safety, and maximised space utilisation. Let’s walk through everything you need to know to make the best choice for your business.
Understanding Your Storage Needs First
Before diving into types and specifications, you need to understand exactly what you’re storing and how you’ll be accessing it. This might seem obvious, but it’s surprising how many businesses rush into purchasing warehouse racking without properly assessing their requirements.
Start by measuring your products and pallets – both dimensions and weight. The standard UK pallet size is 1200mm x 1000mm, but you might be using different sizes. Your heavy duty racking needs to accommodate not just your current inventory, but also consider future product lines you might introduce.
Think about your picking patterns too. Do you need access to every pallet individually, or are you storing the same product in bulk? This will influence whether you need selective racking or can benefit from higher-density storage solutions.
Types of Pallet Racking Systems
Selective Pallet Racking
This is your bread-and-butter solution – the most common type of warehouse racking you’ll see. Every pallet position is accessible from the aisle, making it perfect for facilities with diverse stock keeping units (SKUs). It’s straightforward to install, easy to reconfigure, and works with most forklift types.
The main advantage? You can access any pallet at any time without moving others. The trade-off is that it uses more floor space than high-density alternatives, but for most businesses, the accessibility benefits outweigh this consideration.
Drive-In and Drive-Through Racking
When you need to maximise storage density and you’re dealing with multiple pallets of the same product, drive-in systems are brilliant. Your forklift literally drives into the racking structure to place or retrieve pallets. Drive-in means one entry point (pallets go in and come out the same way), while drive-through has entry and exit points at opposite ends.
This storage racking solution can increase your storage capacity by up to 75% compared to selective racking, but remember – it works on a last-in, first-out basis, so it’s not suitable for products with expiry dates.
Push-Back Racking
This clever system uses inclined rails and gravity to automatically move pallets forward when you remove the front one. You can store 2-6 pallets deep per lane, offering a good balance between storage density and selectivity. It’s particularly useful for medium-velocity products where you don’t need constant access to every pallet.
Pallet Flow Racking
Also known as gravity feed racking, this system uses rollers or wheels on inclined tracks. Pallets are loaded from the back and automatically roll forward to the picking face. It’s perfect for high-turnover products and creates an efficient first-in, first-out system.
Key Considerations for Your Purchase
Load Capacity and Safety
This isn’t the place to cut corners. Your heavy duty racking needs to handle not just the weight of your products, but also the dynamic forces from forklift operation. UK regulations require that racking systems include a safety factor, typically 1.5 times the stated load capacity.
Always work with the combined weight of pallet plus product, and don’t forget to factor in seasonal peaks when you might be storing more than usual. At Rackline, our UK manufactured shelving is designed and tested to exceed British and European safety standards, giving you peace of mind that your investment is built to last.
Aisle Width Requirements
Your aisle width determines which forklifts you can use and affects your overall storage density. Standard counterbalance forklifts typically need 3.5-4 metres of aisle width, while reach trucks can work in narrower aisles of around 2.8 metres. Very narrow aisle (VNA) trucks can operate in aisles as narrow as 1.8 metres, but require guided systems.
Remember, narrower aisles mean more storage space but potentially slower picking speeds. It’s about finding the right balance for your operation.
Adjustability and Future-Proofing
Your business will evolve, and your storage shelving solutions should be able to adapt. Look for systems that allow you to easily adjust beam heights and reconfigure layouts. This flexibility is particularly valuable if you’re growing rapidly or if your product mix changes seasonally.
Quality racking systems use standardised components, making it easier to expand or reconfigure your setup later. This is where investing in reputable UK manufactured shelving pays dividends – you’ll find replacement parts and expansion components readily available.
Warehouse Applications and Use Cases
Manufacturing and Production
In manufacturing environments, pallet racking often needs to handle raw materials, work-in-progress, and finished goods. You’ll typically want selective racking near production lines for easy access to components, with bulk storage areas using higher-density solutions for raw materials.
Distribution and Logistics
Distribution centres benefit from mixed racking solutions. Fast-moving consumer goods might use pallet flow systems, while slower-moving items work well with selective racking. The key is creating zones that match your picking patterns and delivery schedules.
Retail and E-commerce
Retail operations often need flexible warehouse racking that can handle everything from small parcels to bulk pallets. Many successful e-commerce operations use selective racking for individual order picking combined with bulk storage areas for replenishment stock.
Cold Storage and Specialised Environments
If you’re operating in cold storage, your industrial shelving needs to handle temperature fluctuations and potential condensation. Galvanised or stainless steel options provide better corrosion resistance, while ensuring your racking maintains structural integrity in challenging conditions.
The UK Manufacturing Advantage
When you choose UK manufactured shelving, you’re not just buying a product – you’re investing in quality, reliability, and service. British manufacturing standards are among the world’s highest, and you’ll benefit from shorter lead times, easier communication, and local support when you need it.
At Rackline, we understand UK warehouse challenges because we operate in the same environment as our customers. Our storage design team can visit your site, assess your needs, and provide solutions that work in real-world British conditions. Plus, with local manufacturing, we can offer competitive pricing without compromising on quality.
Making Your Final Decision
Getting Accurate Quotes
Don’t just compare headline prices – make sure you’re comparing like-for-like specifications. Ask about delivery costs, installation services, and warranty terms. A slightly more expensive system that includes comprehensive support might offer better value than a basic quote that leaves you handling everything yourself.
Installation and Safety Compliance
Professional installation isn’t just recommended – it’s essential for warehouse safety. Incorrectly installed racking is dangerous and could invalidate your insurance. Look for suppliers who offer SEMA-approved installation services and provide the necessary certification documentation.
Ongoing Support and Maintenance
Your pallet racking system will need regular inspections and occasional maintenance. Choose a supplier who can provide ongoing support, replacement parts, and inspection services. This is another area where working with UK-based suppliers like Rackline offers real advantages – we’re always here when you need us.
Ready to Transform Your Warehouse?
Selecting the right storage racking system is a significant investment, but get it right and you’ll see improvements in efficiency, safety, and space utilisation that benefit your business for years to come.
If you’re ready to explore storage shelving solutions that perfectly match your needs, our team at Rackline is here to help. We offer free site surveys, detailed storage design consultations, and competitive quotes on our full range of UK manufactured shelving systems.
Want to discuss your specific requirements? Get in touch call us on 01782 770144, email us at: info@rackline.co.uk, or fill in the form below and one of our team will be in touch.