Push Back Racking: What is it and How it Works

Introduction

For distribution centers and storage facilities, the pursuit of space utilization retains great purports. As real estate costs soar and consumer demand fluctuates.

To counter this situation, many warehouses have been leveraging warehouse storage solutions such as Pushback racking, a powerful tool in this quest for space utilization, offering a blend of density and accessibility.

What is a Pushback Racking System

Pushback racking represents a high-density storage method designed to maximize vertical space utilization while maintaining selectivity.

This system allows for the storage of multiple pallets deep on either side of an aisle, significantly increasing storage capacity compared to traditional selective racking.

The core principle behind pushback racks revolves around a series of nested carts or rollers on slightly inclined rails. As new pallets enter the system, they literally "push back" the existing inventory, creating a compact storage arrangement.

This ingenious design facilitates a last-in, first-out (LIFO) inventory management approach, ideal for operations handling non-perishable goods or those with minimal product rotation requirements.

Mechanics of Pushback Racking

The functionality of pushback racking hinges on a straightforward yet effective mechanism:

1.Loading Process:

o    Forklifts deposit pallets onto the frontmost cart or roller bed

o    Subsequent pallets push the previous ones deeper into the lane

o    This continues until the lane reaches capacity (typically 2-6 pallets deep)

2.Retrieval Process:

o    The forklift removes the frontmost pallet

o    Gravity causes the remaining pallets to glide forward

o    Each extraction reveals the next pallet, maintaining accessibility

This dynamic system ensures that inventory remains easily accessible while maximizing storage density. The slight incline of the rails facilitates smooth pallet movement, reducing the risk of jams or operational delays.

Types of Pushback Racking Systems

Two primary variants of pushback racking dominate the market, each offering unique advantages:

1.Cart-Based Pushback Systems:

*Most widely used and recognized type

o    Utilize nested wheeled carts (also called trolley or shuttle) for pallet movement

o    Offer greater flexibility in terms of pallet sizes and weights

o    Typically allow for deeper storage lanes (up to 6 pallets)

2.Roller-Based Pushback Systems:

o    Employ inclined roller tracks for pallet flow

o    Generally more cost-effective for shallower storage needs

o    Ideal for operations with consistent pallet sizes

The choice between cart and roller systems often depends on specific operational requirements, budget constraints, and the physical characteristics of the stored inventory.

Key Components of Pushback Rack Systems

A standard pushback racking system comprises several essential elements:

• Frames: Vertical supports that bear the load of the entire system
• Beams: Horizontal members connecting frames and supporting the rails
• Rails: Inclined tracks guiding the movement of carts or pallets
• Carts or Rollers: Facilitate the smooth flow of pallets within the system
• Safety Stops: Prevent pallets from accidentally sliding off the back of the rack
• Load Guards: Protect the system from potential forklift impacts

These components work in concert to create a safe, efficient, and durable storage solution capable of withstanding the rigors of daily warehouse operations.

Advantages of Pushback Racking

Pushback racking offers numerous benefits that make it an attractive option for many warehouses:

• Enhanced Storage Density: Increases capacity by up to 90% compared to selective racking
• Improved Selectivity: Provides access to multiple SKUs from a single aisle
• Reduced Aisle Requirements: Minimizes the need for multiple access aisles
• Faster Loading/Unloading: Enables efficient pallet handling and reduced forklift travel
• Inventory Visibility: Allows for easy stock monitoring and management

Potential Limitations to Consider

While pushback racking offers significant benefits, it's essential to consider potential drawbacks:

• LIFO Inventory Management: May not suit operations requiring strict first-in, first-out rotation
• Limited Depth: Typically restricted to 2-6 pallets deep
• Pallet Integrity: Requires sturdy pallets to withstand the pushing mechanism
• Initial Cost: Higher upfront investment compared to some traditional racking systems
• Vertical Space Loss: Slight incline may reduce overall vertical storage capacity

Careful evaluation of these factors against operational needs ensures the most suitable storage solution selection.

Ideal Applications and Industries

Pushback racking excels in various scenarios and industries, including:

• Cold Storage: Maximizes expensive refrigerated space
• Manufacturing: Supports efficient storage of raw materials and finished goods
• Distribution Centers: Enhances order fulfillment capabilities
• Retail Warehouses: Facilitates storage of fast-moving consumer goods
• Automotive Parts Storage: Accommodates diverse inventory with high turnover rates

Operations handling multiple SKUs with moderate quantities per product line often find pushback racking particularly beneficial.

Sizing and Dimensional Considerations

Effective implementation of pushback racking requires careful attention to sizing:

• Lane Depth: Typically ranges from 2 to 6 pallets deep
• Bay Width: Standard configurations include 96" double-wide or 48" single-wide bays
• Height: Limited by facility constraints and forklift reach, often 16' to 20' tall
• Pallet Dimensions: System design must accommodate standard pallet sizes (e.g., 40" x 48" GMA pallets)

Customization options allow for tailoring the system to specific facility requirements and inventory characteristics.

Cost Factors and ROI

The investment in pushback racking varies based on several factors:

• System Complexity: Cart-based systems generally cost more than roller-based alternatives
• Storage Depth: Deeper lanes increase per-pallet costs
• Materials and Finishes: Galvanized or stainless steel options for corrosion resistance add to costs
• Safety Features: Additional guards or impact protection increase overall expenses

Typical costs range from $150 to $400 per pallet position. Despite higher initial outlays, pushback racking often delivers substantial ROI through:

• Increased storage capacity
• Reduced labor costs
• Improved inventory management
• Enhanced operational efficiency

A thorough cost-benefit analysis, considering both immediate expenses and long-term operational gains, guides informed decision-making.

Is Pushback Racking Right for Your Operation?

Determining the suitability of pushback racking requires a comprehensive evaluation of your operational needs:

• Inventory Characteristics: Ideal for non-perishable items with moderate turnover rates
• Storage Density Requirements: Beneficial when maximizing cubic storage is crucial
• SKU Diversity: Supports storage of multiple product lines in a single system
• Handling Equipment: Requires forklifts capable of reaching and maneuvering at height
• Budget Considerations: Demands higher upfront investment for long-term efficiency gains

If you still have any puzzles on the right fit for your warehouse, don’t hesitate to contact us now, rack specialists from Vison Storage are ready to conduct a comprehensive evaluation and ensure the optimal storage solution selection for your unique requirements.