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New & Used Pallet Racking: Maximize Storage, Minimize Cost

July 15, 2024

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When you walk into your business's storage room or warehouse, do you think, "What lunatic designed this?" Perhaps, something a little less polite? Maybe you're one of the lucky people who doesn't get headaches from doing inventory or looking through stock. If not, or if your warehouse is bursting at the seams but still has vertical space, it's time to invest in expanding your storage. Usually, this will mean more pallet racks.

Pallet racking is an excellent solution to horizontal storage problems and disorganization. With pallet racks, you can maximize your storage capacity and improve efficiency.

In this post, JS Rack & Supply is going to lead you on a deep dive into pallet racking. What it is, different types, and the challenge of buying new versus used.

What is Pallet Racking Exactly?

 
Pallet racking systems are the backbones of warehouses and other storage facilities. They consist of a series of upright frames, typically made of heavy-duty steel, that support horizontal beams. These beams create shelves at various heights, designed to hold wooden or plastic pallets loaded with goods.

Unlike floor storage, pallet racking utilizes vertical space to its full potential. This allows you to store a significantly higher volume of inventory in the same square footage. Additionally, pallet racking systems are designed to work seamlessly with forklifts, enabling safe and easy loading, unloading, and organization of your palletized materials.

In essence, these are all-around storage materials–reliable, easy to set up, and easy to use. 
 

Types of Pallet Racking Systems

Let's delve into the most common types of pallet racking systems. Each offer their own advantages, depending on your specific needs.

The most common types of pallet racking systems are: 
  • Selective Pallet Racking
  • Drive-In Racking
  • Push-Back Racking 
  • Cantilever Racking 
  • Mezzanine Racking 

We'll explain each of these in more detail below.

Selective pallet racking is the most versatile and widely used option. It features individual bays of upright frames with horizontal beams creating shelves. Each pallet is easily accessible from the aisle, allowing for efficient loading, unloading, and stock management. This is ideal for situations where you need frequent access to a variety of items.

Drive-in racking, on the other hand, prioritizes high-density storage. Here, the racks themselves become part of the support structure, creating lanes where forklifts can drive directly into the racking system to deposit and retrieve pallets. This maximizes storage capacity by eliminating wasted aisle space. However, it's important to note that drive-in racking follows a Last-In-First-Out (LIFO) inventory management system, as accessing pallets deeper in the lane requires removing those placed in front.

Pushing the boundaries of storage efficiency, push-back racking utilizes a gravity-fed system. Slightly angled shelves on carriages are loaded with pallets that roll back under their own weight as additional pallets are added. The front-most pallet is always accessible, making it ideal for FIFO (First-In-First-Out) inventory management.

For storing long, bulky items that don't fit on standard pallets, cantilever racking offers a perfect solution. Imagine horizontal arms extending out from a single upright post, creating shelves like spokes on a wheel. These cantilever arms can be adjusted to accommodate various lengths and sizes of materials, making them ideal for pipes, lumber, or furniture.

And lastly, if you've exhausted your upward storage potential but still crave more space, mezzanine racking provides a creative solution. Essentially, it elevates a secondary platform within your existing warehouse using the footprint of your pallet racking system. This creates a valuable upper level for additional storage or office space, maximizing your cubic storage capacity without sacrificing valuable floor space.

Buying New vs. Buying Used

Like many other new versus used debates, buying new or buying used pallet storage racks each has advantages and disadvantages. Used racking might be unsightly or have stability problems you won't see right away. New racking will come at a higher price.

New Pallet Racking:

Pros:
  • Latest safety features and compliant with current standards.
 
  • Durable, long lifespan, and minimal maintenance.
 
  • Manufacturer warranty and support for any issues.


Cons:
  • Higher upfront cost compared to used options.
 
  • May require longer lead times for custom configurations.


Used Pallet Racking:

Pros:
  • Significant cost savings compared to buying new.
 
  • Often in excellent condition and perfectly functional.
 
  • More environmentally friendly by reusing existing materials.


Cons:
  • Potential for hidden damage or rust, requiring inspection.
 
  • May not be compatible with existing systems if expanding.
 
  • No manufacturer warranty or support; buyer beware.


Tips for buying used pallet racking safely:
 
  • Inspect thoroughly for damage or rust
 
  • Ensure compatibility with your existing system (if applicable)
 
  • Verify certifications and load capacities

Expanding pallet racking storage

Even with an existing pallet racking system, there are ways to maximize your storage capacity without needing a complete overhaul. Here are some tips:
 
  • Utilize Vertical Space Effectively: Many racking systems allow for adding upper levels. Evaluate your warehouse height and forklift capabilities to determine if additional shelves are feasible.
 
  • Double-Deep Racking (with Caution): This strategy stores two pallets deep within each bay. While it increases capacity, it requires specialized forklifts and comes with safety considerations. Consult a professional to ensure it is suitable for your setup.
 
  • Optimize Aisle Width: Analyze your forklift's turning radius and maneuverability to determine the optimal aisle width between racking units. Even small reductions in aisle space can translate to significant storage gains.
Looking ahead, consider these options for future expansion:
 
  • Adding Bays or Sections: Modular racking systems allow for adding additional upright frames and beams to create more bays or extend existing rows, providing a seamless way to increase storage capacity.
 
  • Upgrading to a Different Racking Type: If your needs have evolved, consider a different racking system altogether. For instance, selective racking for easy access might transition to high-density storage with drive-in racking if access frequency is less critical.

Pallet racking systems offer a powerful solution to maximize storage capacity and streamline warehouse operations. Whether you choose new racking with its cutting-edge features and warranties, or explore the cost-effective options of used racking, there's a perfect solution for your specific needs. Remember, even with an existing system, there are strategies to optimize your space.

By implementing these tips and considering future expansion options, pallet racking can become a key ally in achieving a more organized, efficient, and productive warehouse environment.

For all of your storage needs, call JS Rack & Supply at (503) 233-7791 or contact us online. We are based in Molalla, OR, with a secondary location in Ontario, OR. This places us conveniently near both the Portland, OR and Boise, ID areas. We provide services nationwide. 
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