What’s The Best Warehouse Storage Solution For You?

What’s The Best Warehouse Storage Solution For You?

Choosing the right warehouse storage solutions is crucial for any organisation. There are many types of warehouse storage systems to choose from, each with their own advantages. From static shelving and pallet racking to multi-tier racking and mezzanine flooring, making the right choice for your operations can feel daunting. With the right guidance, however, you can cost effectively transform your workplace’s operation efficiency and storage capacity.

Explore the warehouse storage solutions available, so you can make an informed decision that you’re confident is right for your business.

Multi-Tier Racking

Another type of pallet racking, multi-tier racking utilises previously untapped vertical space potential in your warehouse. The system is adaptable across multiple workplaces as tiers can be removed and added depending on your current requirements. Unfortunately, there isn’t a one-size-fits-all storage solution that is perfect for every warehouse, regardless of industry. Multi-tier racking, however, is flexible enabling you to adapt it to your requirements, existing space, and inventory.

Supporting hand-loaded shelving levels, multi-tier racking systems make picking easier while utilising the available space to its maximum potential. If your warehouse stores small parts, ships for an eCommerce site, or manages a pick and pack operation, multi-tier racking systems allow you to store and retrieve items fast.

Multi-tier racking offers high-density storage capacity, improved picking operations across different levels, and increased productivity. If you require access to all locations in the warehouse, staff can conveniently pick from any area of the setup. Multi-tier racking is a cost-effective solution for online retailers and any organisation storing small parts.

Mezzanine Flooring

Mezzanine flooring can transform your entire warehouse, from the operations to the aesthetics. Mezzanines are cost-effective, quick to assemble, and create space for storage and administration. The cube encompasses the available space in your warehouse. Across most warehouse designs, the vertical space in the cube is often underutilised meaning there is unused storage space. Incorporating mezzanine flooring into your warehouse utilises this vertical space, often doubling or tripling the surface area available to you.

A self-contained construction, mezzanine floorings are simple to assemble and adapt to any location. Because a mezzanine level is free-standing and demountable, it can also be easily transported to your future premises. A multi-tier mezzanine is a multi-level system that supports shelving systems that are manually loaded. You can incorporate multi-tier staircases, loading areas with pallet gates, and administration areas into your mezzanine.

Working with warehouse design consultants ensures you install a mezzanine that matches your requirements. Our team at SEC Storage can guide you through the different types of warehouse storage systems, so you secure the best option for your warehouse.

Pallet Racking

Pallet racking is a versatile storage solution that is adaptable to many industries, workplaces, and inventories. They enable you to manage high demand and fast production requirements as you can store large quantities of palletised goods. Pallets utilise space more efficiently, speed up picking and organising times, and create adaptable storage spaces. Any pallets are placed on the pallet racking system using a forklift or an automated device, depending on the structure’s height.

High-density storage solutions like pallet racking allow you to take advantage of previously untapped space in your warehouse. This is why pallet racking is a cost-effective choice, allowing you to secure a return on your investment, as well as improve operational efficiency. Despite storing more items in close proximity, the risk of inventory being damaged is decreased as pallet racking systems are strong and durable.

There are a variety of pallet racking systems available. Mobile, double deep, and drive-in racking are some examples and all have unique benefits; the right choice depends on your warehouse’s requirements. Assess the weight limits of the pallet racking structures, their adaptability, and how they fit into your existing warehouse. From there, make the decision that matches your operational requirements. Here are some examples of the different types of pallet racking we install:

Wide Aisle Racking

Wide Aisle Racking is one of the most cost-effective and widely used types of pallet racking – the wide aisles ensure easy manoeuvring with 100% product selectivity and 30-45% space utilisation. It does not require any special equipment and works with standard forklifts.

The system is formed of upright frames, pallet support bars and adjustable horizontal beams. It is quick to install, durable and adjustable – which is useful for the storage of new SKUs and goods. It can be re-engineered and reconfigured at any time in the future, so is well suited for SKUs that have a high stock rotation and FIFO (first in, first out) operations.

See an example of how Wide Aisle Racking was used in our project with Welch’s Transport Ltd.

Very Narrow Aisle Racking

Very Narrow Aisle Racking is often used for warehouses with limited space, different unit loads and sizes, and the need to immediately access each unit load. It increases the storage capacity and concentration of pallets on the same footprint by using Adjustable Pallet Racking (APR) to reduce the aisle width between 2.7 and 1.6 meters.

The system allows 100% selectivity, supports FIFO systems and fast operating speeds, and typically utilises 45-55% of space. Pallets can be stored at a greater height than many other storage systems, ensuring maximum use of cubic space. This type of racking requires specialist trucks and wire or rail guidance systems, which minimises the risk of damage, resulting in lower maintenance.

See an example of how we used Very Narrow Aisle Racking in our project with Daler-Rowney.

Double Deep Pallet Racking

Double Deep Pallet Racking provides high-density storage with a reduced number of aisles by storing pallets two deep and back to back. This uses standard pallets but requires a specialist forklift truck attachment. The rear pallet can only be accessed once the front pallet is removed. It is well-suited for SKUs that have a high stock rotation and eliminates unneeded aisles and increases floor space utilisation

This system requires scenarios where 100% selectivity is not required and the front and rear pallet generally store the same product – operating on a LIFO (last in, first out) basis. It can increase pallet storage count by up to 50% and can be reconfigured into standard single-deep and vice-versa.

See how Double Deep Pallet Racking was used in our project with Hendler Wholesale Ltd.

Drive-In/Through Pallet Racking

Drive-In Pallet Racking systems provide high-density and space-efficient pallet storage, which is ideal when space is limited. It maximises the storage per cubic meter and has low capital cost compared to other dense storage solutions, therefore, making it excellent for use in cold stores and refrigerated facilities. It is effective with low numbers of SKUs and high throughputs. Pallets are stored on cantilevered rails, thereby making the load and retrieval of pallets simpler, but also prevents goods from becoming damaged.

Drive-In Pallet Racking provides one entry (generally LIFO) which is suitable for bulk and non-perishable goods. Whereas, Drive-Through systems provide entry and exit at both ends (generally uses FIFO but can also use LIFO) and is better for goods with higher turnover rates.

See how we utilised Drive-In Racking in our project with the Port of Dover.

Push-Back Pallet Racking

Push-Back Pallet Racking is a versatile pallet storage system which uses gravity to store and release pallets in deep configurations. It enables pallets to be stored over four deep. Pallets are placed in the front and subsequent pallets are then added by ‘pushing back’ the front pallet. To retrieve, the process is reversed, with the pallets returning to the pick face under gravity (due to the slightly sloped storage lanes).

Stock rotation is based on the LIFO principle and each lane is typically only dedicated to one SKU. This system allows less than 50% selectivity with medium operating speeds and over 60% space utilisation. Push-Back solutions are very versatile and can cater to a wide range of operations but are particularly suited to warehouses that store non-perishable/long expiration date items, have temperature controlled areas, and have products with a low number of units for each SKU.

See how Push-Back Pallet Racking was used in our project with Domino’s Pizza.

Pallet Live Pallet Racking

Pallet Live Pallet Racking is a high-density, gravity-driven storage system with guaranteed stock rotation for fast-moving products. Working on a FIFO basis, the pallets are stored in a block system which requires separate aisles for input and output operations. Pallets load from the input side onto fixed gradient sloping rollers and roll forward to be retrieved at the picking face. When a pallet is removed the next pallet rolls into place.

This system is perfect for fast-moving products and is accessible for most types of forklift trucks. It is more efficient than other forms of dense storage and can achieve over 60% space utilisation.

See how we used Pallet Live Pallet Racking in our project with Adient Seating UK Ltd.

Pallet Racking Shuttle System

A Pallet Racking Shuttle System is a high-density, compact storage solution that utilises remote-controlled, powered satellites to lift, move and place pallets within the rack with automatic control of inventory. Pallets can be retrieved from any level at any time, thereby providing a higher level of selectivity than other dense storage solutions. Using sensors, shuttles can automatically locate, lift and move pallets from one position within a lane to another. The pallet shuttle runs off of rechargeable batteries and also contains diagnosis software for troubleshooting issues – ensuring maximum up-time.

This system can work as FIFO or LIFO and can be implemented in virtually any environment, including freezer temperatures of -30°C. The level of forklift contact is minimised as the driver only has to load the pallet onto the shuttle, thus reducing damage and improving safety.

We have installed 2D shuttles, designed to travel forward and backward within a storage lane, supporting high-density pallet storage with efficient in-lane movement. You can see this approach in our 4 Aces case study.

We also deploy 4-way shuttle systems, where the shuttle can move in four directions and transfer between lanes autonomously. This reduces the need for forklifts to reposition equipment between lanes and supports quicker access to a wider range of pallet locations. Explore our 4-way shuttle project with Easy Care Solutions Ltd.

Cantilever Racking System

Cantilever Racking is a versatile and robust form of horizontal storage for long or awkward items such as pipes, steel or timber. Products are supported across two or more arms on fitted decks in the heavy duty racking system, which are positioned across runs of cantilever arms. The products are then handled by forklift trucks, crane systems, or manually.

The system is modular, therefore, additional arms, racks, uprights and braces may be added if storage requirements change. It is also possible to create extra-wide shelves to suit loads of varying lengths. Cantilever systems are available in light and heavy duty finishes – the heavy duty version is often wall fixed and can carry a load of up to 5 tonnes per arm and over 30 tonnes per upright. It is available up to 10 metres high and can be used outside if galvanised.

See how we utilised Cantilever Racking Systems in our project with Kawneer UK Ltd.

Mobile Pallet Racking

Mobile Pallet Racking is a high-density storage solution that is good for sites with limited floorspace. The pallet racking is mounted on manoeuvrable bases, made mobile with tracks set into the floor. This provides high-density storage and maximises the use of space as aisles do not need to be left open – it can achieve over 60% space utilisation whilst providing 100% pallet selectivity.

This system supports a FIFO System and has a very slow operating speed which is suitable for slow-moving bulk items. It is a good solution for products which require expensive storage conditions (eg: freezers) and is versatile as many types of racking can be adapted to be mobile.

See how we used Pallet Live Pallet Racking in our project with Kawneer UK Ltd.

Static Shelving

Fitted into a fixed position, static shelving is an ideal choice for open storage locations, especially where a large number of items need to be stored. These structures are designed to be a stable, permanent fixture in your warehouse. If you store high-quantities of lighter weight inventory, static shelving provides a convenient storage solution. Static shelving also makes it simpler for staff to replenish stock if you have a high turnover of inventory in your warehouse.

Typically, static shelving is not compatible with forklifts, so all items must be manually picked. This includes when organising inventory and replenishing stock. If you have a wide range of different items that vary in size and weight, incorporating static shelving alongside other storage solutions is a smart strategy. For any larger inventory, wide-span shelving systems can support heavier items and you can configure the shelves higher above the ground.

SEC Warehouse Design Solutions

Whatever your industry, at SEC Storage, we use data to create intelligent warehouse designs. Our team assesses your requirements and creates a bespoke solution that improves efficiency, is cost-effective, and enables your business to grow. Discover the best types of warehouse storage systems for your workplace by calling our friendly and expert team on 01438 731990 or fill in an enquiry form.