Maximise your warehouse space with the right pallet racking system.
Is your warehouse space running out faster than expected? A pallet racking system can be a game-changer. It can transform crowded storage areas into organised, high-efficiency workspaces. But with so many options—selective racking, drive-in, push-back, and pallet flow—how do you choose the best one for your needs?
A smart system for your space will increase storage, streamline inventory access, and enhance safety. In this guide, we’ll cover each type of pallet racking and show you how to choose the right one for your business. This will allow you to make wise choices that will improve your team’s efficiency while saving you money.
Let’s explore which racking system best fits your space.
Key Highlights
- With warehouse vacancy rates at just 2.89% (UKWA, 2024), businesses must optimise vertical storage to maximise efficiency.
- HSE guidelines highlight that inadequate storage can result in workplace accidents and high legal costs.
- Modular pallet racking solutions adapt to automation, ensuring long-term efficiency and cost savings.
What Is a Pallet Racking System & Why Does It Matter?
A pallet racking system is a warehouse storage method for palletised goods. It uses vertical shelving to make storage more efficient. These systems boost storage capacity by optimising height, not floor space. This way, businesses keep things accessible.
With UK warehouse space at a premium, efficient storage is essential. The UK Warehousing Association (UKWA) reports that warehouse vacancy rates dropped to 2.89% in 2024. This puts pressure on businesses to make better use of their current space instead of expanding.
A well-designed racking system isn’t just for organising stock. It speeds up workflow so employees can get inventory faster, cutting downtime and boosting fulfilment times. Racking is also vital for warehouse safety. It helps meet HSE guidelines by keeping aisles clear and stopping stock from collapsing.
Types of Pallet Racking Systems & Their Best Uses
Choosing the right pallet racking system depends on your:
Warehouse Layout
Available space and aisle width.
Inventory Type
SKU variety, stock turnover, and storage density.
Operational Priorities
FIFO vs. LIFO, automation, and accessibility.
Let’s explore the most common pallet racking systems and their ideal applications:
Selective Pallet Racking
Best for versatility and easy access.
Selective pallet racking is the most widely used system. It offers direct access to every pallet without needing to move others, making it ideal for warehouses storing a diverse range of SKUs that require frequent stock rotation.
Best for
- Businesses that need high accessibility for varied stock.
- Warehouses with wide aisles and regular stock movement.
Considerations
- Requires more aisle space than high-density systems.
- Less space-efficient for bulk storage.
If your warehouse struggles with space constraints, alternatives such as push-back or drive-in racking may be a better fit.
Find a tailored pallet racking solution at First Floors.
Drive-In & Drive-Through Racking
Best for high-density storage.
Drive-in and drive-through racking help save aisle space for bulk storage of uniform products. They allow pallets to be stacked deep in the lanes.
Storage principles
- Drive-in racking uses a LIFO system (Last-In, First-Out), making it best for low-turnover stock such as seasonal goods or raw materials.
- Drive-through racking follows a FIFO system (First-In, First-Out). This makes it essential for perishable goods like food and pharmaceuticals.
A DEFRA report on food waste reduction explains that using FIFO storage helps lower spoilage. It also improves inventory management in warehouses that distribute food.
Learn more about industry storage regulations at HSE.
Push-Back Racking
Best for high-density, fast-turnover inventory.
Push-back racking offers a space-saving option compared to selective racking. It’s ideal for quick-moving, high-density stock. It uses inclined carts that allow pallets to roll forward when the front pallet is removed, reducing aisle space requirements.
Best for
- Warehouses with limited space that need high-density storage.
- Businesses operating on a LIFO (Last-In, First-Out) basis.
Considerations
- Not suitable for FIFO-based inventory management.
Push-back racking is often found in wholesale and manufacturing industries. It helps manage large volumes of the same product that need to be turned over quickly.
How to Choose the Right Pallet Racking System for Your Warehouse
When choosing a pallet racking system, think about three key things. These include your available space, the type of inventory you have, your workflow, and your long-term business goals. Below, we’ll explore the key factors to help you make an informed decision.
Assess Your Warehouse Layout
Before investing in a racking system, it’s essential to evaluate your warehouse’s physical dimensions. Factors such as floor space, ceiling height, aisle width, and forklift access all impact the type of racking that will work best.
- If your warehouse has wide aisles, you can use selective pallet racking. This setup enables forklifts to access pallets individually, making stock retrieval faster and simpler.
- If space is short, high-density systems like drive-in or push-back racking can maximise storage without taking up more area.
A report from Savills UK showed that optimising vertical storage can boost usable warehouse space by up to 40%. Pallet racking is a clever alternative to expanding warehouses, particularly in pricey city areas.
Explore some of our case studies at First Floors.
Analyse Your Inventory & Storage Needs
The type of inventory you store plays a crucial role in choosing the right racking system.
Do you need FIFO (First-In, First-Out) or LIFO (Last-In, First-Out) storage?
- FIFO storage, like pallet flow racking, is crucial for perishable items. This includes food, pharmaceuticals, and temperature-sensitive products.
- LIFO storage (e.g., push-back or drive-in racking) is better suited for bulk storage where stock turnover speed is less critical.
How frequently do you need to access inventory?
- High-turnover stock benefits from push-back or selective racking, which allows for quick retrieval.
- Bulk storage of identical products is best suited to drive-in or drive-through racking.
According to DEFRA, effective stock rotation through FIFO storage systems can significantly reduce product waste in sectors like food distribution and pharmaceuticals.
Read about UK inventory storage regulations on GOV.UK.
Determine Load Capacity & Safety Requirements
Every racking system has limits on how much weight it can hold. Exceeding these limits can lead to warehouse accidents, product damage, and legal problems. Ensuring your system supports your inventory’s weight is critical for efficiency and safety. The Health and Safety Executive (HSE) enforces strict pallet racking safety regulations in the UK.
According to HSE guidelines
- Overloaded or improperly installed racking is a leading cause of warehouse collapses.
- Regular racking inspections help prevent structural failures and operational downtime.
- Rack protection systems should be installed in order to avoid forklift collisions and pallet misalignment.
Learn more about pallet racking inspections at First Floors.
Plan for Future Growth & Scalability
Warehouses need storage solutions that grow with the business. A well-designed racking system should allow for easy expansion, reconfiguration, and automation integration.
- If businesses expect more demand, they should consider investing in modular systems. These can include push-back or drive-through racking, both of which can boost storage density without requiring relocation.
- Is your company considering automation? Ensure their racking system is compatible with warehouse robotics and conveyor-based retrieval systems.
Take Control of Your Warehouse Storage Today
Your warehouse is key to your operations. Choosing the right pallet racking system can boost efficiency, ensure safety, and save money in the long run. With the proper storage solution, you can save space, increase workflow, and meet UK safety standards.
Key Takeaways
- A well-planned racking system increases efficiency and reduces wasted space.
- Routine inspections and correct weight distribution prevent accidents and compliance issues.
- Modular, scalable systems allow your warehouse to adapt and grow with demand.
At First Floors, we specialise in custom pallet racking solutions for businesses of all sizes. Whether you need high-density storage or a system prioritising easy access, our experts are here to help. The sooner you use the right racking system, the quicker you’ll have a more organised, productive, and cost-effective warehouse.
Call us on 01789 764172 to book a free consultation today or request a storage assessment.
