Push Back Pallet Racking

Push back pallet racking is a type of storage system used in warehouses that allows pallets to be stored on either side of an aisle and creates a higher-density storage solution than traditional pallet racking.

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High-Density Storage

Increased Efficiency

Better Stock Management

Push Back Racking Systems

What Are Push Back Pallet Racking Systems?

A push back pallet racking system is a dynamic operation where a forklift pushes a pallet into a bay, which causes the pallets already stored there to be pushed backwards. When the pallet at the front is removed, the one behind it will automatically roll to the front. Pallets can be stacked up to six deep and up to five pallets high, using space effectively and allowing for easy organisation of stock. The system uses a First In, Last Out (FILO) system with conventional forklifts and uses more than twice the floor space of wide aisle racking.

Advantages:

  • Improved efficiency
  • Reduced risk of product damage
  • Cost-effective storage
  • Quick and easy access
  • Effective for bulk and cold storage
  • Ideal for stock with predictable storage
pallet live racking diagram

Push back pallet racking specifications will vary based on the specific needs of the warehouse but generally include:

  • Dimensions – push back racking systems are designed to accommodate standard pallet sizes, although they can be customised for different pallet dimensions.
  • Heights – the height of a push back pallet racking system can vary greatly depending on the ceiling height of the warehouse and the reach capability of the material handling equipment.
  • Lane Width Designed to suit the pallets to allow for easy placement and retrieval allowing forklifts or pallet movers to manoeuvre between.
  • Load Capacity – the materials used for the construction will result in the weight capacity of the system overall and each push back racking system can be created for your company’s requirements.

Accessories

Push back pallet racking can be equipped with a variety of accessories to enhance functionality, safety and efficiency. Some of these accessories include:

  • Row Spacers – these connect back to back rows of racks for extra stability and consistent spacing.
  • Cart and Rail Components – additional carts or replacement rail components can be bought for maintenance and to expand the system’s capabilities.
  • Labelling and Signage – having correct labels and signage for safe and efficient operation is essential. They can indicate weight capacities, loading instructions and safety warnings
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Benefits of Push Back Racking

Improved Warehouse Storage Efficiency

Push back racking systems significantly enhance warehouse efficiency. By enabling pallets to be loaded and unloaded from the same side, the system streamlines operations, reducing the time and effort required to manage inventory. This setup minimises the need for forklift operators to manoeuvre around different aisles, allowing for quicker and more direct access to pallets and the condensed storage design reduces the overall distance forklifts need to travel, leading to faster operation times and less wear on equipment. This efficient handling process not only speeds up day-to-day operations but also minimises potential bottlenecks in the warehouse workflow.

Risk of Product Damage Reduced

The design of push back pallet racking inherently reduces the risk of product damage. Since forklifts do not have to enter the racking lanes, there is significantly less chance of them bumping into and damaging the racks or the stored goods. This aspect is crucial for warehouses storing fragile or high-value items. The pallets in a push back rack are also less likely to shift or fall, as they are securely nested on carts or rails. This stable storage environment protects products from the common risks associated with movement and vibration and the reduced need for frequent handling of the pallets also means the products are less exposed to potential mishandling.

Cost-Effective Warehouse Storage Alternative

Push back racking systems is a cost-effective storage solution, primarily due to its high-density design. By allowing storage of pallets up to several deep, it maximises the use of warehouse space. This efficient space utilisation can eliminate the need for expensive warehouse expansions or additional storage facilities. Additionally, the reduced labour costs associated with quicker loading and unloading, combined with decreased forklift travel, contribute to overall operational cost savings. The longevity and durability of the system also means long-term maintenance and replacement costs are lower compared to other storage systems.

Quick and Easy Access

Despite being a high-density system, push back pallet racking offers quick and easy access to stored pallets. Each lane in the racking system can be accessed independently, allowing warehouse staff to retrieve specific pallets without having to rearrange or move others. This feature is particularly beneficial in scenarios where quick access to various SKUs is essential. Compared to deeper storage systems like drive-in racks, push back racking provides superior visibility of products, making it easier for operators to find and pick the items they need. This greater visibility and accessibility reduces picking errors and improves overall efficiency in inventory management and general warehouse management.

Effective for Bulk and Cold Storage

Push back pallet racking systems excel in environments where bulk storage is needed such as in wholesale, retail or manufacturing. As it can hold up to six pallets in each lane, it can store significantly more than other, traditional racking systems meaning it’s especially beneficial for storing large quantities of the same product or similar products with the same storage needs. In cold storage facilities where air conditioning and refrigeration costs are high, keeping large and dense products close together will reduce the volume of area that needs to be cooled – meaning energy cost savings.

Ideal for Stock with Predictable Storage

Push back racking operates on a LIFO inventory system which makes it ideal for products with longer shelf lives or those with predictable turnover rates. Goods that don’t require immediate dispatch or where the order of dispatch isn’t critical are easily stored and accessed when needed on push back pallet racking, and it can allow warehouses to efficiently manage their inventory. When a company has predictable sales cycles or consistent product demand, push back racking systems will create a much more streamlined operation – reducing labour costs and minimising time spent on inventory management.

Our Success Stories

Find below a snapshot of some of the work we have recently undertaken, if you would like to know more about them or perhaps you would like to visit the sites please don’t hesitate to get in touch.

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Vadmin Anhimov

3 weeks ago

Quickline Ltd have delivered exceptional service in supplying and installing storage racking. From the initial contact, their team has been professional and…

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Mark Dunne

3 weeks ago

We have worked with Quickline for over 10 years, they are excellent at what they do. The price is competitive and they deliver what they promise.

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David Gutfreund

3 weeks ago

We’ve used Adam and his team on several projects. Most recently installing a 25,000 high bay racking system. Can’t fault them. Competitively priced and delivered on time.

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Ben Rawson

3 weeks ago

Adam and his team of experts have assisted in design and build for 3 of our Distribution Warehouses now. Each time providing an expert service in…

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