Types of pallet racking and their price examples
Pallet racking refers to a storage system designed to hold and organize palletized goods within a warehouse or distribution center. It provides a cost-effective and efficient solution for storing large quantities of goods on pallets, enabling easy access and maximizing storage space utilization. Pallet racking systems are commonly used in various industries, including logistics, manufacturing, retail, and e-commerce.
There are several types of pallet racking systems available, each designed to suit different storage needs and warehouse configurations. Here are some commonly used types of pallet racking:
1. Selective Pallet Racking: Selective pallet racking is the most common and widely used type of racking system. It offers direct access to every pallet, allowing for easy loading and unloading. Pallets can be stored and retrieved individually, making it suitable for operations with a wide variety of SKUs and high stock turnover.
2. Drive-In and Drive-Through Racking: Drive-in and drive-through racking systems are designed for high-density storage with minimal aisles. In drive-in racking, pallets are loaded and retrieved from the same side, creating a last-in, first-out (LIFO) storage configuration. Drive-through racking allows pallets to be accessed from both sides, following a first-in, first-out (FIFO) storage method.
3. Pushback Racking: Pushback racking utilizes a system of nested carts or rails that allow pallets to be stored and retrieved by pushing them along inclined lanes. This system offers high-density storage and provides both selectivity and relatively quick access to multiple pallets. Pushback racking is suitable for applications with multiple SKUs and a limited number of pallets per SKU.
4. Pallet Flow Racking: Pallet flow racking, also known as gravity flow racking, uses inclined roller or wheel tracks to facilitate the movement of pallets. Pallets are loaded from one end and flow by gravity to the other end, following a first-in, first-out (FIFO) storage method. This system allows for high-density storage and efficient inventory rotation.
5. Cantilever Racking: Cantilever racking is primarily used for the storage of long and bulky items, such as pipes, lumber, or steel bars. It consists of vertical columns with horizontal arms that extend outward. The open design of cantilever racking allows for easy loading and unloading of oversized items.
6. Double-Deep Racking: Double-deep racking is a variation of selective pallet racking that allows for higher storage density. It involves placing two pallets deep on each side of the aisle, which requires specialized forklifts or reach trucks with extended forks to access the rear pallet. Double-deep racking is suitable for operations with high storage volume and fewer SKU varieties.
7. Mezzanine Racking: Mezzanine racking utilizes the vertical space above the floor by adding a raised platform or mezzanine level. The lower level typically consists of pallet racking while the upper level can be used for additional storage or as a workspace. Mezzanine racking is ideal for maximizing storage capacity in facilities with high ceilings.
8. Mobile Racking: Mobile racking, also known as mobile shelving or compact racking, is a system where racks are mounted on carriages that move along tracks. This system eliminates the need for multiple aisles as the racks can be compacted together, maximizing storage space. Mobile racking is suitable for applications where space is limited and high-density storage is required.
9. Satellite Racking: Satellite racking, also known as satellite shuttle racking, is an automated system designed for high-density storage and efficient pallet handling. It uses remote-controlled shuttles that move along the rack system, transporting pallets to and from designated positions. Satellite racking is suitable for operations with high pallet turnover and can improve productivity by reducing the need for forklifts.
10. Vertical Racking: Vertical racking, also referred to as vertical storage or vertical carousel systems, utilizes vertical space to store and retrieve goods automatically. The system consists of vertically arranged trays or shelves that rotate to bring the required item to the operator at the picking station. Vertical racking is commonly used for small parts and items with high picking frequency.
11. Live Storage Racking: Live storage racking, also known as dynamic flow racking, is designed for high-density storage and efficient order picking. It utilizes inclined roller tracks or gravity flow lanes to enable the automatic movement of pallets or cartons. Pallets are loaded at one end and flow by gravity to the picking face, ensuring a first-in, first-out (FIFO) storage method.
12. Case Flow Racking: Case flow racking is similar to live storage racking but is specifically designed for cases or cartons rather than pallets. It uses gravity flow lanes with roller tracks or conveyor systems to facilitate the movement of cases from the loading end to the picking end. Case flow racking is commonly used in order picking applications and can improve pick accuracy and efficiency.
13. Dynamic Drive-In Racking: Dynamic drive-in racking combines the benefits of drive-in racking with gravity flow principles. It allows for high-density storage with the first-in, first-out (FIFO) inventory rotation. Pallets are loaded onto inclined roller tracks, and as one pallet is retrieved, the next pallet rolls forward automatically.
14. Hybrid Racking Systems: Hybrid racking systems are customized solutions that combine different types of racking systems to meet specific storage requirements. For example, a combination of selective racking, drive-in racking, and pushback racking can be used to optimize storage space and accessibility based on the characteristics of the stored goods.
15. Rack Supported Buildings: Rack supported buildings, also known as structural racking systems, are designed to support the entire structure of a building. The racking system acts as the framework for the building, providing both storage space and structural integrity. This type of system is ideal for large-scale warehousing operations where maximizing storage capacity is a priority.
16. AS/RS (Automated Storage and Retrieval System): AS/RS is a highly automated system that uses robotic cranes or shuttles to handle the storage and retrieval of pallets. The system operates based on computerized controls and can efficiently manage inventory, track stock movements, and optimize storage space. AS/RS is suitable for high-volume distribution centers and warehouses where speed, accuracy, and space utilization are critical.
17. Pallet Shuttle System: The pallet shuttle system is an automated solution that uses a shuttle device to move pallets within the racking system. The shuttle operates on rails and can transport pallets deep into the racking, allowing for high-density storage and efficient inventory management. This system is particularly useful for operations with a large number of pallets per SKU.
18. Mobile Shelving: Mobile shelving, also known as mobile storage systems or compact shelving, is a system where shelves are mounted on mobile carriages that move along tracks. The system eliminates the need for fixed aisles, as the shelves can be compacted together. Mobile shelving is commonly used for storing smaller items and can significantly increase storage capacity.
19. Pick Modules: Pick modules are multi-level storage and picking systems that combine pallet racking with mezzanine platforms, conveyors, and picking stations. They are designed to facilitate efficient order picking and can incorporate various storage methods, such as selective racking, carton flow, or pallet flow. Pick modules are suitable for high-volume distribution centers and e-commerce operations.
20. Cold Storage Racking: Cold storage racking is specifically designed for refrigerated or frozen environments where temperature-controlled storage is required. These racking systems are constructed using materials and coatings that can withstand low temperatures without compromising structural integrity. Cold storage racking ensures the safe and efficient storage of perishable goods.
21. VNA (Very Narrow Aisle) Racking: VNA racking is designed to maximize storage density by utilizing very narrow aisles and specialized narrow aisle forklifts or guided picking systems. The aisles in VNA racking are significantly narrower than traditional selective racking systems, allowing for more efficient use of space. VNA racking is suitable for warehouses with high ceilings and a large number of SKUs.
22. Gravity Racking: Gravity racking, also known as gravity flow racking or dynamic racking, uses inclined roller tracks or conveyor systems to enable the automatic movement of pallets or cartons by gravity. Pallets or cartons are loaded at higher elevations and flow down to lower picking positions. Gravity racking is ideal for applications with high order picking rates and FIFO inventory management.
23. Carousel Racking: Carousel racking, also known as horizontal carousels or vertical carousels, is an automated storage and retrieval system that consists of rotating shelves or carriers. The system brings the required shelf or carrier to the operator for picking or replenishment. Carousel racking is suitable for small parts or items with high turnover rates and can significantly improve order picking efficiency.
24. Coil Racking: Coil racking is specifically designed to store and handle coils, such as steel or wire coils. The racking system consists of specially designed cantilever arms or cradles that provide support and secure storage for coils. Coil racking allows for safe and organized storage of heavy and bulky cylindrical loads.
25. Rack Clad Buildings: Rack clad buildings combine the structural support of a building with an integrated racking system. The racking system forms the walls and part of the roof structure of the building, providing storage space while also acting as the building's framework. Rack clad buildings are suitable for operations that require both storage capacity and a dedicated facility.
26. Dynamic Picking Racking: Dynamic picking racking combines the benefits of pallet racking with gravity flow principles for efficient order picking. It utilizes inclined flow lanes and dedicated picking positions to facilitate the movement of products to the pickers, improving productivity and reducing picking time.
27. Carton Flow Racking: Carton flow racking, also known as case flow racking, uses inclined roller tracks or conveyor systems to facilitate the movement of cartons or cases from the loading end to the picking end. It allows for efficient order picking and replenishment, with a focus on maximizing storage density and improving picking accuracy.
28. Automated Guided Vehicles (AGV) Racking: AGV racking combines automated guided vehicles with pallet racking systems. The AGVs are used to transport and position pallets within the racking system, eliminating the need for manual forklifts. This system offers high automation and can be integrated with warehouse management systems for efficient inventory management.
29. AS/RS with Crane: AS/RS (Automated Storage and Retrieval System) with crane is a highly automated system that uses robotic cranes to handle the storage and retrieval of pallets. The cranes operate within a controlled environment and can access pallets from multiple levels of racking. AS/RS with crane systems are suitable for high-volume, high-density storage and can significantly increase storage capacity while reducing labor requirements.
30. Rack Supported Mezzanine: Rack supported mezzanines utilize the lower level of pallet racking as the support structure for an elevated mezzanine floor. This allows for additional storage space above the racking system while maintaining structural integrity. Rack supported mezzanines are commonly used when there is a need for both pallet storage and additional floor space for operations or offices.
31. Mobile Pallet Racking: Mobile pallet racking consists of racks mounted on motorized bases that can be moved laterally to create access aisles. This system allows for more efficient use of space by eliminating the need for multiple fixed aisles. Mobile pallet racking is controlled by a remote or integrated control system and is suitable for operations where space optimization is crucial.
32. Hybrid Pushback Racking: Hybrid pushback racking combines the features of pushback racking and selective racking. It allows for both high-density storage and selectivity by utilizing pushback lanes for some pallets and selective lanes for others. This system provides a balance between storage density and accessibility based on the specific needs of different SKUs.
33. High Rise Racking: High-rise racking refers to racking systems designed for warehouses with exceptionally high ceilings. These systems maximize vertical storage space by utilizing taller uprights and customized configurations. High-rise racking is commonly used in large distribution centers or facilities with limited floor space but ample height.
34. Rack Enclosures: Rack enclosures, also known as rack enclosures or wire mesh enclosures, are used to secure and protect specific areas within a pallet racking system. They provide a physical barrier around designated sections of the racking to prevent unauthorized access or to segregate specific product categories or high-value items.
Prices of pallet racking
The prices of pallet racking systems can vary significantly depending on multiple factors, including the type of system, size, configuration, quality, and additional features. Additionally, prices can vary based on geographical location and market conditions. It's important to obtain specific quotes from reputable suppliers or manufacturers for accurate pricing information. However, here are some approximate price ranges for different types of pallet racking systems, based on general market trends and average costs:
1. Selective Racking: Prices for selective racking typically range from $50 to $150 per pallet position, depending on the size, height, and load capacity of the system. This range includes the cost of uprights, beams, and necessary accessories.
2. Drive-In Racking: Drive-in racking tends to be more expensive than selective racking due to its higher storage density. Prices can range from $200 to $400 per pallet position, considering factors such as the number of pallets deep, height, and load capacity.
3. Cantilever Racking: Cantilever racking is commonly used for storing long and bulky items. Prices for cantilever racking can range from $200 to $600 per upright, depending on the height, arm length, and load capacity.
4. Pushback Racking: Pushback racking offers high-density storage with dynamic pallet flow. Prices for pushback racking can range from $200 to $400 per pallet position, depending on factors such as the number of pallets deep, height, and load capacity.
5. Satellite Racking: Satellite racking systems involve automated shuttles, which can significantly increase the overall cost. Prices for satellite racking can range from $500 to $1,500 per pallet position, depending on the complexity of the system and the number of shuttles required.
6. VNA (Very Narrow Aisle) Racking: VNA racking systems, which require specialized narrow aisle forklifts, tend to be more expensive due to their precision and design. Prices for VNA racking can range from $150 to $300 per pallet position, considering factors such as height, depth, and load capacity.
7. AS/RS (Automated Storage and Retrieval System): AS/RS systems involve high levels of automation, including robotic cranes or shuttles. Prices for AS/RS systems can vary significantly depending on the complexity, size, and customization. As a rough estimate, prices can range from $500 to $1,500 per pallet position or more for a complete AS/RS system.
8. Carton Flow Racking: Carton flow racking systems, which utilize inclined roller tracks, tend to have lower overall costs compared to some other types of racking. Prices for carton flow racking can range from $30 to $100 per linear foot, considering factors such as the length, number of levels, and additional features.
9. Mobile Pallet Racking: Mobile pallet racking systems, with their motorized bases and lateral movement capability, generally have higher costs compared to traditional static racking. Prices for mobile pallet racking can range from $300 to $600 per pallet position, considering factors such as system size, features, and automation level.
10. Rack Supported Mezzanine: Rack supported mezzanine systems utilize existing racking as the support structure for an elevated floor, providing additional storage space. Prices for rack supported mezzanines can range from $50 to $150 per square foot, depending on the size, load capacity, and customization requirements.
11. Automated Guided Vehicles (AGV) Racking: AGV racking systems, which incorporate automated guided vehicles, can have significant costs due to the integration of sophisticated robotics. Prices for AGV racking systems can range from $500 to $1,500 per pallet position or more, depending on system complexity, number of vehicles, and customization.
12. Gravity Racking: Gravity racking systems, which use inclined roller tracks or conveyor systems, offer efficient product flow by gravity. Prices for gravity racking can range from $100 to $300 per pallet position, depending on factors such as length, number of levels, and customization options.
13. Carousel Racking: Carousel racking systems, utilizing rotating shelves or carriers for automated storage and retrieval, tend to be higher in cost due to their advanced automation. Prices for carousel racking can range from $1,000 to $3,000 per storage position, depending on the size, capacity, and level of customization.
14. Coil Racking: Coil racking systems, designed for storing cylindrical loads such as steel or wire coils, have varying price ranges depending on the size and load capacity requirements. Prices for coil racking can range from $200 to $500 per upright, considering factors such as height, arm length, and load capacity.
15. Rack Clad Buildings: Rack clad buildings combine the structure of a building with an integrated racking system, providing both storage space and a dedicated facility. Prices for rack clad buildings can vary significantly based on factors such as building size, complexity, and customization. As a rough estimate, prices can range from $100 to $300 per square foot or more.
16. Dynamic Picking Racking: Dynamic picking racking systems, which combine pallet racking with gravity flow principles, offer efficient order picking. Prices for dynamic picking racking can range from $100 to $250 per pallet position, considering factors such as the number of flow lanes, length, and customization requirements.
17. Hybrid Pushback Racking: Hybrid pushback racking systems, combining pushback and selective racking features, provide a balance between storage density and accessibility. Prices for hybrid pushback racking can range from $150 to $350 per pallet position, depending on the depth, height, and load capacity.
18. High Rise Racking: High-rise racking systems, designed for warehouses with high ceilings, can have higher costs due to their specialized construction and taller uprights. Prices for high-rise racking can range from $100 to $250 per pallet position, considering factors such as height, load capacity, and customization options.
19. Rack Enclosures: Rack enclosures, offering security and protection for specific areas within a pallet racking system, vary in price depending on the size and level of customization. Prices for rack enclosures can range from $50 to $200 per linear foot, considering factors such as height, length, and additional features.
20. Dynamic Pallet Flow Racking: Dynamic pallet flow racking systems, using inclined roller tracks for automatic product movement, can have varying price ranges based on system size and customization requirements. Prices for dynamic pallet flow racking can range from $150 to $350 per pallet position, depending on factors such as depth, length, and load capacity.
21. Shuttle Racking: Shuttle racking systems utilize automated shuttle vehicles to transport and store pallets within the racking structure. Prices for shuttle racking can range from $300 to $600 per pallet position, depending on factors such as shuttle quantity, system size, and customization.
22. Multi-Tier Racking: Multi-tier racking systems incorporate multiple levels of racking to maximize vertical storage space. Prices for multi-tier racking can range from $100 to $250 per square foot, considering factors such as the number of levels, load capacity, and customization.
23. Mobile Shelving: Mobile shelving systems, also known as compact shelving, feature movable shelves that create space-efficient storage. Prices for mobile shelving can range from $250 to $500 per linear foot, depending on factors such as system size, shelving material, and customization.
24. Satellite Racking with Conveyor: Satellite racking systems combined with conveyor systems offer automated pallet handling and storage. Prices for satellite racking with conveyor can range from $600 to $1,500 per pallet position, considering factors such as the number of shuttles, conveyor length, and customization.
25. Pallet Flow Racking: Pallet flow racking systems utilize inclined roller tracks to achieve first-in, first-out (FIFO) product rotation. Prices for pallet flow racking can range from $150 to $300 per pallet position, depending on factors such as track length, depth, and load capacity.
26. Rack Protection Accessories: Rack protection accessories, such as column protectors and guardrails, enhance safety and prevent damage to the racking system. Prices for rack protection accessories can range from $50 to $200 per unit, depending on the type, size, and material.
27. Bulk Storage: Bulk storage systems, designed for storing large quantities of non-palletized items, have varying price ranges based on system size and customization. Prices for bulk storage can range from $50 to $150 per square foot, considering factors such as capacity, shelving type, and customization options.
28. Pallet Shuttle System: Pallet shuttle systems use specialized shuttle devices to transport pallets within the racking structure, maximizing storage density. Prices for pallet shuttle systems can range from $400 to $800 per pallet position, depending on factors such as shuttle quantity, system size, and customization.
29. Pick Modules: Pick modules are customized systems that combine racking, conveyor systems, and picking stations for efficient order fulfillment. Prices for pick modules can vary widely based on system complexity, size, and customization, typically ranging from $100 to $300 per square foot.
30. Case Flow Racking: Case flow racking systems utilize inclined roller tracks to facilitate the flow of cases or cartons for order picking. Prices for case flow racking can range from $100 to $250 per linear foot, depending on factors such as track length, depth, and load capacity.
31. Dynamic Carton Storage: Dynamic carton storage systems feature roller tracks or conveyor systems to facilitate the movement and storage of individual cartons. Prices for dynamic carton storage can range from $75 to $200 per square foot, considering factors such as system size, customization, and additional features.
32. Vertical Lift Modules (VLM): VLM systems use an enclosed structure with vertically arranged trays that automatically deliver requested items to an ergonomic workstation. Prices for VLM systems can range from $20,000 to $50,000 per unit, depending on tray capacity, height, and customization.
33. AS/RS Mini-Load System: AS/RS mini-load systems are automated storage and retrieval systems designed for handling small items or totes. Prices for AS/RS mini-load systems can range from $100,000 to $500,000 or more, depending on system size, complexity, and customization.
34. Rack Inspection and Maintenance Services: Rack inspection and maintenance services are essential for ensuring the safety and longevity of your racking system. Prices for inspection and maintenance services can vary depending on the size of the system, location, and scope of work. It's recommended to contact service providers for a detailed quote.
35. Used/Refurbished Pallet Racking: Used or refurbished pallet racking offers a more cost-effective option compared to purchasing new systems. Prices for used or refurbished pallet racking can vary significantly based on factors such as condition, size, and availability in the market. It's advisable to consult with suppliers or resellers for specific pricing information.
Please note that the provided price ranges are approximate and can vary based on factors such as location, system specifications, customization requirements, and market conditions. It's advisable to consult with reputable suppliers, manufacturers, or service providers to obtain accurate pricing based on your specific needs and location.