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Understanding the Distinction between Drive-In Pallet Rack and Push-Back Pallet Rack

Authored by Derek Rotondi
July 3, 2023

Efficient warehouse storage is crucial for businesses aiming to optimize their operations. When it comes to pallet racking systems, there are various options available, each designed to meet specific storage needs. Among these options, Drive-In Pallet Rack and Push-Back Pallet Rack are popular choices. In this blog post, we will explore the key differences between these two systems, their benefits, and the factors to consider when choosing between them.

Drive-In Pallet Rack:

Drive-In Pallet Rack is a high-density storage solution that maximizes available space. It is designed for storing large quantities of the same product or SKU (Stock Keeping Unit). Here's how it works:

  • Structure: Drive-In Pallet Rack features a series of closely spaced rails that support the pallets. These rails are placed horizontally and vertically, creating a series of lanes.
  • Loading: Forklifts or reach trucks enter the rack structure to place and retrieve pallets. The forklifts drive directly into the lanes, allowing pallets to be stored back-to-back and side-by-side.
  • Last-In, First-Out (LIFO): Drive-In Rack operates on a Last-In, First-Out system, meaning the last pallet loaded into a lane is the first to be retrieved. This configuration is suitable for businesses with large quantities of the same product, where product rotation is not critical.
Pallet Rack
Pallet Rack
Flow Rack
Drive-In Rack
Drive-In Rack

Benefits of Drive-In Pallet Rack:

  • Maximized storage capacity: Drive-In Rack allows for efficient use of space, making it ideal for products with long shelf life or bulk storage.
  • Reduced aisle space: Since forklifts can enter the rack structure, the need for wide aisles is eliminated, enabling more efficient space utilization.
  • Cost-effective: Drive-In Rack requires fewer aisles, reducing construction and operating costs.
  • Suitable for temperature-controlled environments: The high-density design of Drive-In Rack is particularly advantageous in cold storage facilities.

Push-Back Pallet Rack:

Push-Back Pallet Rack is another popular choice for high-density storage. It operates on the Last-In, First-Out principle, offering versatility and ease of use. Here's an overview of its functioning:

Push-Back Pallet Rack is another popular choice for high-density storage. It operates on the Last-In, First-Out principle, offering versatility and ease of use. Here's an overview of its functioning:

  • Structure: Push-Back Rack consists of a series of nested carts or trays that are inclined toward the front of the rack. These carts are mounted on inclined rails, allowing for gravity-assisted movement.
  • Loading: Pallets are loaded onto the carts from the front aisle. When a new pallet is loaded, it pushes the existing pallets backward along the inclined rails.
  • Last-In, First-Out (LIFO): Push-Back Rack also operates on a Last-In, First-Out system, with the last pallet loaded being the first to be unloaded.

Benefits of Push-Back Pallet Rack:

  • Flexibility: Push-Back Rack allows storage of multiple SKUs in the same lane. Each level can accommodate a different SKU, enhancing flexibility and order selectivity.
  • Accessibility: With Push-Back Rack, all pallets are accessible from the front aisle, simplifying inventory management and improving picking efficiency.
  • Efficient space utilization: Push-Back Rack optimizes space utilization by utilizing both depth and height of the rack, making it suitable for applications where product rotation is important, but storage space is limited.
  • Reduced forklift travel: Since each level is loaded and unloaded from the same aisle, forklift travel distance is minimized, resulting in faster material handling operations.
  • Choosing the Right System:

    Selecting the appropriate pallet racking system depends on various factors, including product characteristics, storage requirements, inventory turnover, and operational preferences. Consider the following when deciding:

    • Product shelf life and rotation requirements
    • Number of SKUs to be stored
    • Available warehouse space
    • Budget constraints
    • Desired accessibility and picking efficiency
    • Equipment compatibility (forklift types and sizes)

    Conclusion:

    Both Drive-In Pallet Rack and Push-Back Pallet Rack offer efficient high-density storage solutions for businesses. Drive-In Rack is suitable for bulk storage of the same SKU, while Push-Back Rack provides more versatility and accessibility for multiple SKUs. By understanding the key differences between these systems and considering your specific requirements, you can make an informed decision to optimize your warehouse storage and enhance overall operational efficiency.