Warehouse space is tight these days for a myriad of reasons. If you’re looking to get inventory and supplies off the floor and into a safer, more efficient storage solution, the good news is you have options. Shelving uses vertical space, creating open floor space and usually a better, safer warehouse flow. When examining system options, consider the type of inventory you store and how you access it. Choices range from high-density, high-capacity pallet racking to sturdy, easy-to-assemble industrial shelving. Here’s a breakdown of the reliable options and best-use practices to help you make an informed choice.
While standard pallet rack and shelving are both go-to warehousing tools classified by RMI as material handling structures, they serve distinct functions. Let’s consider why and when you would choose one over the other.
The primary function of a pallet rack system is to store palletized materials loaded by forklifts, lift trucks, cranes, and pallet trucks. Because they are accessed by material handling equipment capable of reaching significant heights and carrying heavy loads, pallet racking is best utilized for maximizing vertical space and bearing high load capacities.
A standard, free-standing pallet rack system is comprised of vertical uprights and horizontal cross beams. The rack is anchored to the floor via baseplates attached at the base of the uprights. Rows of rack can also be connected with overhead ties and or row spacers (depending on layout) to provide additional system support.
Pallet racking does not require a solid decking surface to place inventory. Instead, pallets in a standard rack system straddle the front and rear beams. However, it is often recommended to add pallet supports or wire decking between the beams to safeguard against falling items. Wire decking can also open up the opportunity to use the lower levels of the rack for hand-stacked items. This is a good way to utilize a rack system fully; however, steel shelving can pose another good option for hand-stacked inventory.
There are four main pallet rack system designs. The most basic, standard selective, compares most similarly to steel shelving systems –this is the one used for the comparison above. However, high-density systems such as drive-in, pallet flow, and push-back systems create deep lanes of pallet storage on multiple levels to optimize cube space and consolidate worker travel time and resources.
Unlike pallet rack, shelving is typically used for hand-loaded inventory and odd-shaped item storage. System heights are limited to human height or step ladder access. Additionally, while lightweight to heavy-duty steel gauge options exist, capacity is typically limited to load weights under 1000 lbs. Clearly, 1000 lb loads aren’t considered stackable by hand; however, the shelving is compatible with lifting devices such as a vacuum lifter. Lastly, industrial shelving typically uses a solid surface such as wood, composite, or metal to form the shelf.
Steel shelving is quick to assemble and easy to relocate, primarily because of the simple upright-to-shelf connections and the fact that they are not anchored into the ground. Despite installation ease, they provide a very durable storage option.
There are two main options when choosing a commercial shelving system –boltless and bin.
Boltless Shelving, also called rivet shelving, is most similar to pallet racking in that it requires uprights and shelf beams, but as noted earlier, a full-surface decking is attached to the beams. This type of shelving is easy to customize by width and depth to create the storage solution that fits your space and inventory needs.
Bin Shelving is typically used for individual bins, totes, and boxes for small item storage. The upright depth is limited to 12” – 24”, accommodating a reasonable reach distance. Widths can range from 12” – 60”. Shelves can be a solid surface or specially designed for individual storage organizers, and you can add side and back panels if desired.
A deeper storage option for totes and boxes for high-volume products is carton flow rack –wheeled or roller rails that install into the lower levels of a pallet rack system or as a stand-alone storage rack for order picking, assembly, kitting, etc.
Maximizing your space is the best way to get the most from your operational dollar. Consolidated storage units minimize the costs associated with travel and equipment use. Plus, they improve order processing and assembly activity efficiency. The Apex team can help you make the right choices. Our warehouse design and systems experts will create the most economical solution for your operation. Call today for prompt service.
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