Start with Your Inventory to Choose Pallet Racking
The right warehouse storage system depends on your inventory, not just floor space. Many SKUs with low stock levels need flexible access, while fewer SKUs in large quantities may suit deep-lane pallet racking.
Build an inventory profile covering:
- SKU count and stock levels: typical, peak and seasonal pallets per SKU.
- Loaded pallet dimensions: include packaging and overhang.
- Pallet weight: record maximum loads and weight distribution.
- Peak throughput: measure inbound and outbound pallet movements.
- Stock rotation: identify date, batch and expiry requirements.
Check lane occupancy before choosing a layout. Partially filled, single-SKU lanes can reduce usable storage capacity, even when a system offers more pallet positions.
8 Types of Pallet Racking Systems Compared
| Pallet Racking Type | Relative Storage Density | Pallet Accessibility | Stock Rotation | Best-Suited Inventory | Equipment Requirements and Key Trade-Offs |
|---|---|---|---|---|---|
| Selective Pallet Rack | Standard; comparison baseline | Direct access to every pallet | FIFO or LIFO through inventory management | Many SKUs with relatively few pallets per SKU | Compatible with conventional forklifts selected for aisle width and lift height; flexible access, but more floor space dedicated to aisles |
| Shuttle Pallet Rack | High; suitable for deep storage lanes | Sequential access within each lane | Typically LIFO with single-ended access; FIFO possible with access at both ends | Large quantities of pallets per SKU and batch movements | Semi-automatic systems require forklifts and powered shuttles; throughput depends on shuttle availability and forklift coordination |
| Mobile Pallet Rack | High; reduces fixed access aisles | Direct access once the required aisle opens | FIFO or LIFO through inventory management | Many SKUs where space efficiency and individual pallet access are priorities | Requires powered mobile bases and controls; aisle-opening time can limit simultaneous operations |
| Pallet Flow Rack | High | Sequential retrieval from the discharge end | FIFO in standard loading-at-one-end, unloading-at-the-other configurations | Multiple pallets per SKU with frequent turnover | Gravity rollers move pallets through inclined lanes; pallet condition, load characteristics and roller compatibility require validation |
| Push-Back Rack | Medium–high to high | Sequential access from one working aisle | LIFO | Multiple pallets per SKU without strict FIFO requirements | Forklifts remain outside the rack; each lane typically holds one SKU, and inner pallets cannot be accessed directly |
| Very Narrow Aisle Rack (VNA) | Higher than conventional selective layouts | Direct access to every pallet | FIFO or LIFO through inventory management | Many SKUs requiring individual access and improved space utilisation | Typically requires specialised VNA trucks; floor quality, guidance and pallet transfer arrangements need coordinated planning |
| Double Deep Pallet Rack | Higher than single-deep selective layouts | Rear pallets are blocked by front pallets | Typically LIFO within each paired storage position | Multiple pallets per SKU where reduced selectivity is acceptable | Requires double-deep handling capability; poor front-and-rear stock allocation can increase pallet reshuffling |
| Drive-In & Drive-Through Rack | High | Sequential access; forklifts enter storage lanes | Drive-in: typically LIFO; drive-through: FIFO possible with suitable operating procedures | Few SKUs with large quantities of pallets per SKU | Forklifts operate inside the rack; dense storage comes with slower manoeuvring and greater exposure to rack impacts |
FIFO vs. LIFO: How Pallet Racking Affects Stock Rotation
IFO (First In, First Out) is an inventory rotation method in which the first pallet stored is the first retrieved. It helps prevent older stock from accumulating and suits products that require regular stock rotation. In dedicated FIFO racking layouts, pallets are typically loaded at one end and retrieved from the other.
LIFO (Last In, First Out) means the last pallet stored is the first retrieved. Loading and unloading usually take place from the same aisle, supporting compact storage. This method suits products without strict stock rotation requirements, but older pallets may remain in storage until newer stock is removed.
FIFO and LIFO Pallet Racking Systems
| Stock Rotation Method | Pallet Racking Systems | Key Feature |
|---|---|---|
| FIFO (First In, First Out) | Pallet Flow Rack | Pallets are loaded from one side and retrieved from the opposite side, so the first pallet stored is the first pallet picked. |
| FIFO (First In, First Out) | Drive-Through Rack | Pallets are loaded from one end and retrieved from the other end, allowing FIFO operation when procedures are followed. |
| FIFO (First In, First Out) | Shuttle Pallet Rack — double-ended layout | Pallets enter from one side and are retrieved from the opposite side. |
| LIFO (Last In, First Out) | Push-Back Rack | All loading and retrieval occur from the same aisle; the last pallet loaded moves to the front for retrieval. |
| LIFO (Last In, First Out) | Drive-In Rack | Forklifts enter and retrieve pallets from the same side of the storage lane. |
| LIFO (Last In, First Out) | Shuttle Pallet Rack — single-ended layout | Pallets are loaded and retrieved from the same end of each lane. |
| Typically LIFO | Double Deep Pallet Rack | The front pallet must be removed before the rear pallet can be accessed. |
| Flexible: FIFO or LIFO | Selective Pallet Rack | Each pallet has direct access, so the rotation method is determined by inventory rules and picking procedures. |
| Flexible: FIFO or LIFO | Very Narrow Aisle Rack (VNA) | Direct pallet access allows operators to follow the required stock rotation rule. |
| Flexible: FIFO or LIFO | Mobile Pallet Rack | Pallets remain individually accessible after the required aisle is opened. |
Check Your Building and Handling Equipment
A pallet racking layout must fit your building, forklift fleet and daily workflow. Plan around columns, doors, loading areas, pedestrian routes and vehicle traffic. Measure the clear height to the lowest obstruction, as this determines the usable rack height.
Key factors to assess include:
- Forklifts: truck model, turning radius, lift height, attachments and load capacity.
- Working aisles: confirm the required aisle width with the forklift manufacturer for the intended pallet and handling task.
- Building conditions: assess floor loading, anchoring and structural suitability before installation.
- Operational space: reserve room for receiving, dispatch, crossings and replenishment.
Fire protection, access and building requirements should be confirmed during the warehouse racking design process. Local regulations determine the final clearances and approvals for each site.
Check Your Building, Handling Equipment and Load Specifications
A pallet racking layout must suit your building, forklift fleet, pallet loads and daily workflow. Plan around columns, doors, loading areas, pedestrian routes and vehicle traffic. Measure the clear height to the lowest obstruction, as this determines the usable rack height.
Before designing a racking system, provide complete load specifications for every pallet type. Include loaded pallet dimensions, pallet type, maximum pallet weight, load distribution, overhang, packaging and whether loads can be safely stacked. These details determine the required beam capacity, frame capacity, rack configuration and handling equipment.
Key factors to assess include:
- Forklifts: truck model, turning radius, lift height, attachments and rated capacity at the intended lift height.
- Working aisles: confirm the required aisle width with the forklift manufacturer for the specific pallet load and handling task.
- Building conditions: assess floor loading, slab condition, anchoring and structural suitability before installation.
- Operational space: reserve room for receiving, dispatch, crossings, battery charging and replenishment.
Fire protection, access and building requirements should be confirmed during the warehouse racking design process. Local regulations determine the final clearances, load limits and approvals for each site.
Turn your shortlist into a clear project enquiry
Use the checklist above to prepare your requirements before contacting Ronnderack. Include your project location and floor plan so the enquiry starts with the constraints that matter.
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