Cantilever Racks

Cantilever Racks offer a powerful material-handling tools that requires no external bracing. It features either single upright or double upright design that allows for storage of oddly shaped materials or supplies with exceptionally long measurements.

Cantilever Rack offer more use of the vertical cube and help reduce the costs of expansion and moving. Their specific value lies in their ability to store items that cannot be stacked or easily organized in crates or shelving.

Cantilever racks can sit back against the wall with arms extended, giving easy access to manual loading or forklift maneuvering and do not a separate aisle or special access point to reach.

All racks offer a great deal of durability because of a powder coat finish that makes them very tough under hard working conditions.

Single-sided uprights customize easily to a number of individual applications. Double-sided uprights allow for faster manual loading and forklift access. One cantilever rack can store many different types of items because of the adjustable nature of the arms.

Pallet Stacking Frames

Pallet stacking frames are either frames attached to standard wooden pallets or self -contained steel units made up of decks and posts. Stacking frames are portable and enable the user to stack material several loads high. When not in use, the frames can be disassembled and stored in a minimum amount of space.

Stacking frames are commonly used when loads are not stackable and when other racking alternatives are not justifiable. Also, because stacking frames can be leased, they are popular when there is a short-term spike in inventory and the frames are needed to increase storage density in what is normally open floorspace.

A single stacking frame costs between $100 and $300. The storage density losses due to honeycombing described earlier for block stacking also apply to stacking frames.

Pallet Management System

Benefits of pallet management systems:

• Availablilty of pallets is improved and therefore increased asset utilization. The advanced decision making is easier and thus, saving time and money


• Expensive pallets could be purchased at a more efficient level and therfore reducing significant amount of capital


• Warehouse space could be better utiilize and therfore creating a huge saving in warehouse space

Please refer to the below picture for a better overview of Pallet management system:

Click on the picture for a bigger and clearer view

Therefore with a good pallet management system, we could achieved better storage system in the warehouse

Lean-Lift

Lean lift is a fully automated storage retrieval system that brings the required package to the retrieval zone in a few seconds. This could reduce cycle times drastically. Lean lift could reduce the storage system by 60% where it utilizes the available ceiling height which is similar to a high-bay, therefore storing on a height optimised basis which could save space in storage.


The control system of the lean lift is able to communicate with the host computer on a real time basis and therefore allowing the inventory status is readily available. This way, shortages are avoided and inventory can be reduced efficiently.

Vertical Carousels are a general class of storage machine that utilizes chain and track / linkages that rotate box structure shelving modules in a vertical plane.

Vertical carousels resemble a ferris wheel in dynamics, the individual shelving modules are kept horizontal on their path around the vertical track with the use of mechanism.

This is basically using the combination of the chain path of the machine and the secondary GUIDE TRACK and STABALIZING ARMS to shelves the items.

Vertical carousels are available in many load carrying capacities, shelf module dimensions and overall height.

Vertical carousels range from household kitchen pantry consolidation to large industrial units loaded to many tons and heights of 40 feet and more.

Vertical carousels are suited for consolidating the storage of like sized small parts in a small footprint, as the technology is somewhat expensive on a purely volumetric basis.

My personal reflections:

I remembered during my SIP period, my warehouse manager also told me that COURTS (S) is also using this storage system for certain inventories. The advantage for this system he told me is that this system enables FIFO. Which helps to clear the most early stocks first. this helps to prevent obsolete inventories.

A gravity storage system, or live storage, gravity-feed rack assembly or apparatus, characterized by modular units or bays each comprising vertical side frames and horizontal shelf frames. Track and guide means for storage and gravity feed of the racked stock or merchandise. Means for adjustably laterally positioning, and releasably vertically holding down, said track and guide means on said shelf frames.

Sharing time!

I have actually also observed IKEA having this storage idea. They filled the long net with small cushions then drop it into the big trays. When a cushion is being retrived, the subsequent cushions stacking up there will drop.

Single-Deep Pallet Rack 2

A typical single-deep rack position costs between $40 and $50. The major advantage is full accessibility to all unit loads. The major disadvantage is the amount of space devoted to aisles - typically 50 to 60 percent of the available floor space. As a result, in cases where there are three or more pallets on-hand of a SKU, a storage method that houses at least two pallets in a facing perpendicular to the storage aisle is preferable.

Selective pallet rack might be considered the benchmark storage mode, against which other systems may be compared for advantages and disadvantages. Most storage systems benefit from the use of at least some selective pallet rack for SKUs whose storage requirement is less than three to five pallet loads.

Single-Deep Pallet Rack 1

The most popular pallet storage systems are

- Block stacking

- Double-deep rack

- Drive-in rack

- Drive-thru rack

- Push-back rack

- Single-deep selective rack

- Pallet flow rack

- Stacking frames

The blue colour ones have been introduced before. Here i want to describe single-deep pallet rack about its pros, cons, and related costs.

Single-deep pallet racking is a simple construction of metal uprights and cross-members providing immediate access to each load stored (that is, no honeycombing). Unlike block stacking, when a pallet space is created by the removal of a load, a pallet opening is immediarely available in single-deep racking. Also, because racking supports every load, stacking height is not limited by the stackability and/or crushability of the loads, and multiple SKUs can be stacked in the same vertical column of storage space.

Loads do not need to be stackable and may be of varying heights and widths. In distances where the load depth is highly variable, it may be necessary to provide load supports or decking.

Block Stacking

Block stacking refers to unit loads stacked on top of each other and stored on the floor in storage lanes (blocks), two to ten loads deep. Depending on the weight and stability of the loads, stacks may range from two loads high to a height determined by

- Acceptable safe limits

- Load stackability

- Load weights

- Pallet conditions

- Floor loading restrictions

- Weather (due to corrugated softening in high humidity)

- Vehicle lift height capacity

- Crushability of the loads

- Building clear height

Loads in a block should be retrieved under a last-in-first-out (LIFO) discipline. Hence, if highly restrictive FIFO requirements are in place, block stacking is not a feasible storage method. Block stacking is particularly effective when there are multiple pallets per stock keeping unit (SKU) and when inventory is turned in large increments, that is, several loads of the same SKU are received or withdrawn at one time.

As loads are removed from a storage lane, a space-loss phenomenon referred to as honeycombing occurs with block stacking. Because only one SKU can be effectively stored in a lane, empty pallet spaces are created that cannot be utilised effectively until an entire lane is emptied. Therefore, in order to maintain high utilisation of the available storage positions, the lane depth (number of loads stored from the aisle) must be carefully determined.

Because no racking is required, the investment in a block stacking system is low, block stacking is easy to implement, and it ables near-infinite flexibility for floorspace configuration.

Narrow Aisle Racking Storage Systems

2 views of a narrow aisle system using a bespoke shelf system. This design is to accommodate any type size and extreme weight of pallet.

Narrow aisle high bay heavy duty pallet racking using low profile guide rail guidance.

Narrow aisle high bay heavy duty pallet racking system. Note extra horizontal bracing at low level on the frames to increase strength and stability. This system includes pallet support bars for each pallet location.

Narrow aisle heavy duty pallet racking system with cantilever P & D stations at transfer aisle end. Guide rails are concrete re-inforced to allow spread of the extremely heavy loads forced on the frame uprights.

Mobile Racking Storage Systems 2

A motorised base running on inset floor level tracks supporting heavy duty racking or shelving allowing maximum utilisation of warehouse space and 100% access to the pallets / goods.

The systems allows the operator, either in the form of a push button fixed to the racks or a hand held remote control device attached to the fork lift if necessary, to open the aisle with a single command.

The above images show the assembly process of the bases. The bases are delivered in knock down form for assembly on site. The tracks / running rails are generally installed and levelled before the concrete / cement is laid.

Mobile pallet racking with pallets reversed to 1200mm deep, 3 per level - a generally a more cost effective method of storage of pallets.

An example of a lighter duty high bay mobile storage system for archive boxes - hand operated.

The following video describes how the mobile system works. Enjoy it!

http://www.youtube.com/watch?v=YkVFi9FpGW4

Mobile Pallet Racking System 1

Mobile pallet racks are essentially single-deep pallet racks on wheels or tracks permitting an entire row of racks to move away from adjacent rack rows. The underlying principal is that aisles are only justified when they are being used; the rest of the time they are occupying valuable space. Access to a particular storage row is achieved by moving (mechanically or manually) the adjacent row and creating an aisle in front of the desired row. As a result, less than 10 percent of the floorspace is devoted to aisles, and storage density is the highest of any of the pallet storage alternatives. Unfortunately, the pallet storage retrieval productivity is the lowest of any of the alternatives. Hence, mobile racks are justifiable when space is scarce and expensive, and for slow-moving SKUs with one to three pallets on-hand. The cost of typical mobile rack is in the range of $250 per pallet podition.

A mobile storage solution has many advantages over fixed shelving in terms of space utilisation. Only 1 access aisle is needed. The mobile units can be moved singularly or together, generating an aisle as and where it is required, creating almost double the storage capacity.

Very Narrow Aisle and High Bay Storage Systems

When very narrow aisle and high bay storage systems are needed, Automated Storage and Retrieval Systems (AS/RS) is often used to store inventory, buffer processes, and sequence products as needed.

AS/RS systems can handle a wide variety of product units such as cartons, totes, and pallets. In addition, AS/RS systems provide very accurate inventory control information systems and can accommodate a wide variety of product types including raw materials, work-in-process, and finished goods.

Two of the primary drivers for using AS/RS are that they reduce labor and provide consistent sequenced material flow to downstream packing or shipping operations.

AS/RS makes excellent use of the vertical cube space available to store more product in a given footprint thus serving as an excellent solution for very narrow aisle and high bay storage system applications.

The in-feed and discharge locations can be at multiple levels on the end or sides of the AS/RS. Typical AS/RS applications include:

• Freezer/cooler storage and picking since they are typically tough environments for operators.


• Consolidation buffers since they collect various line items for an order and then release the order all together when all line items are available.


• Burn-in testing for electronic items or cooling/curing buffers.


• High security items which need to be isolated from operators.


• Assembly operations (sequencing).


• Point-of-use buffers allowing Kan Ban generated product requests to quickly be transferred to the assembly area.


• Sortation or sequencing of discharged product.

Storage space with combine efforts of mechanisms and technologies make great STORAGE SYSTEM.

Empty Pallet Storage

A common warehouse problem: empty and loose pallets cluttered around loading dock. This isn't only an aesthetic problem; it's also a safety problem and an operational inefficiency! Over-Dock storage racks help solve this problem by storing empty pallets, in racking, above the loading docks. There are two distinct designs: Single-Leg Design & Ceiling Supported Design.




Single-Leg Design

The single-leg design uses an upright frame with a special offset, and a single upright column that clears the door height. Heavy-duty wall ties stabilize the frame. Wall tie and beam length are varied to clear doors. Design adds no load to the roof structure.

Ceiling Supported Design

The ceiling support design muat be designed and verified with the building architect during development of building. Rack frames are bolted, or welded, to the roof trusses of building. This design provides for no floor level legs that may interfere with forklift traffic.

Pallet Flow Rack

Functionally, pallet flow rack is used like drive-thru rack. However, loads are conveyed (FIFO) on skate wheel conveyor, roller conveyor, or rails from one end of a storage lane to the other. As a load is removed from the front of a storage lane, the next load advances to the pick face.

The main purpose of the pallet flow rack is to provide high throughput pallet storage and retrieval and good space utilization. Hence, it is used for those items with high pallet inventory turnover and with several pallets on-hand. The major disadvantage of pallet flow rack is the expense-$200 to $300 per storage position.

Flow Storage consists of two elements: a static rack structure and dynamic flow rails. The flow rails are a track/roller system set at a decline along the length of the rack. Flow rails allow loads to move by gravity from the loading end to the unloading end. Each flow lane includes self-energized speed controllers (brakes) to gently control the speed of movement within the flow lanes. As a load is removed, the loads behind it move forward to the unloading position. The flow system depth, height, and width are limited only by the size of your facility and the capabilities of your material handling equipment. Flow Storage solutions are used in situations where storage density and inventory rotation are priorities.

The Advantages of Flow Rack Systems:

1. First-in, first-out (FIFO) inventory control.

Loads are transported, via the flow rails from the loading end to the unloading end of the storage system. The first load in is always the first load to be taken out. This constant stock rotation is especially beneficial with perishable or time-sensitive goods, such as food or pharmaceuticals, where a lost product becomes a lost profit.

2.Reduced handling costs.

Once loaded, product rotation is automatic. The SK3400 rack eliminates labor and fork truck operation to rearrange loads. And Steel King flow rails are powered by gravity, requiring no electricity or other utilities.

3.Reduced handling equipment costs.

Fork lifts are required only for the initial loading and final unloading. Because only two aisles are necessary, aisle space can be reduced by 75 percent. Fewer fork lifts, operating fewer hours, and consuming less fuel can accomplish the same handling function.

4.Time and labor savings.

With only two aisles, each dedicated to specific functions (loading or unloading), traffic is more orderly, employees are more efficient and overall productivity is improved.

5. Space savings.

Because storage density can be doubled, storage capacity can be increased within the same storage area, or a portion of your existing storage area can be made available for other uses.

6. Construction cost savings.

By increasing storage capacity within existing facilities, the need for new construction could be eliminated. When new construction is necessary, building size and cost can be reduced by up to 50 percent. A smaller warehousing area, in turn, can reduce insurance, land acquisition costs, and taxes.

7.Operating expense reduction.

Higher density storage and consequently smaller storage areas also mean less area to heat, illuminate, air condition, and/or refrigerate.

8. Decreased fork lift damage.

Decreased fork lift handling of loads can result in less product damage and less potential for collision damage to the rack structure.

9.Flexibility.

Flow storage systems have been successfully installed as a part of virtually every storage function, including raw materials receiving and storage, work-in-process, buffer storage, finished goods, order picking, and cross docking.

Drive-In Pallet Racks 2

Double Entry Drive In Rack

Double Entry Racks - lift trucks can enter from both sides or a row of racks. The center of the rack row is stabilized by a beam.

Single Entry Drive In Rack

Single Entry Racks - lift trucks can enter the rack from only one side.

When should you specify Drive-In Racks?

-When you have seasonal items that move quickly out of your inventory.

-When you have a large amount of similar items that can be stored in a single pallet position and accessed last-in, first-out.

-If you don't store a wide variety of loads in the rack.

Drive-In Pallet Racks 1

Drive-in pallet rack requires fewer aisles, allowing to store up to 75% more pallets in the same space.

Drive-In Racks allow a lift truck to enter the rack from one side to pick up or pull out pallets. This is done because pallets can slide backwards on a continuous rail. Forklifts drive into the rack to access pallets two or more deep. You are limited in the depth of storage for a particular bay by the size of your facility. Drive-In racks are typically subject to more abuse than selective racks due to the way they are utilized, so rack integrity and strength are important factors. It is ideal rack for cooler or freezer applications.

Drive-In Racks offer the ability to store a large amount of similar loads in a smaller area. Selectivity is sacrificed, but storage density is outstanding. Drive In Racking can store up to 75% more pallets in the same space than selective racking. It requires fewer aisles and is better cubic storage.

One drawback of drive-in rack is the reduction of lift truck travel speed needed for safe navigation within the confines of the rack construction. Another drawback is the honeycombing losses because no more than one SKU should be housed in a lane. As a result, drive-in rack is best used for slow to medium velocity SKUs with 20 or more pallets on-hand. As was the case with block stacking, loads should be retrieved with a LIFO discipline and with a retrieval discipline to free up each lane as quickly as possible.

Push Back Rack Systems

Push Back Pallet Rack Systems are last-in, first-out storage.

How Push Back Racks work: Pallets are placed by forklift on nested carts riding on inclined rails. Each pallet is then pushed back by subsequent pallet loading, exposing the next cart. When removing product, the forklift takes out the front pallet, allowing the pallets on carts behind it to roll gently to the front of the rack. The nested carts make placement and retrieval easy.

View a Pushback Rack animation:
http://www.steelking.com/products/dynamicStorage/pushback.html

A push Back rack system fills the storage cube with product, not aisles. Instead of single pallet-deep selective racks, a Pushback rack system allow store pallets 2 to 5 deep while retaining easy access to a variety of different SKUs.

Why pushback rack systems?

1. Better use of warehouse space - Push back offers up to 90% more product storage than selective rack systems.

2. Store a variety of SKUs on different levels of lanes for easy product access.

3. Interlocking carts help percent dangerous jamming and costly product damage.

4. Increased selectivity - up to 400% more selectivity than drive-in racks.

5. High storage density coupled with selectivity for faster pick rates.

6. Color coded carts for easy visual inventory.

7. Large target for loading and unloading.

8. Maximizes space utilization.

9. "Last in, first out" inventory.

Drive-Through Rack

Drive-thru rack is merely drive-in rack that is accessible from both sides of the rack. It is for staging loads in a flow-thru fashion where a pallet is loaded at one end and retrieved at the other end. The same consideration for drive-in rack apply to drive-thru rack.

-Loads are supported by rails attached to the upright beams.

-Lift trucks are driven between the uprights beams.

-Requires similar-width loads.

-Open at both ends, allowing access from both ends (FIFO).

Automated Warehousing

Automated Warehousing is based on Automatic Storage and Retrieval Systems (AS/RS), automated robotic systems for storing and retrieving items in a warehouse. Solutions are tailored for industry purposes such as production storage, WIP warehouse, cold or deep-freeze storage, distribution centers and more. It aims to maximize use of storage space, supporting scalability and future growth, increasing productivity and refining stock reliability, while lowering stock levels and allowing a larger stock catalogue.

Modern warehouse system design offers infinite innovative possibilities. The main factors taken into consideration are product type, product diversity, number of articles, performance requirements and other company requirements.

The major mechanical components of an automated warehouse are the cranes (AS/RS machines) and the racking (shelving) system.

Racking system can be either a standalone shelving system within a conventional building, or part of a rack-supported building. Heights may vary from 8 meters to over 40 meters. These can be designed and built as combinations of:

Single deep storage systems
Double deep storage systems
Multi-deep storage systems
Gravity (flow rack) storage system

For more information, Please look at the video:

http://www.youtube.com/watch?v=Cbj2d_0w24E

Pallet Racks

Warehouse racks can include pallet racks, storage racks, shelving rack, cantilever rack, mezzanine rack, catwalk rack, and almost any other type of steel racking systems. Warehouse racking comes in many forms and is used for light duty rack applications to heavy duty rack applications.

Warehouse racking used for pallet storage is the most common system found in warehouses. Pallet racks come in different sizes to accommodate the many various pallet sizes. Pallet racking is either rolled-formed or structural racks. Also, pallet racks are manufactured and engineered for light duty loads such as apparel, to heavy duty loads like cement and tile. Warehouse pallet racking can be modified to better handle certain applications or to increase the storage density within a warehouse. One such example is with pushback pallet racks.

Push-Back pallet racking is high density pallet storage. It allows product to be stored two, three, or four deep. Pallets are retrieved and fed from one aisle allowing for the first pallet-in to become the last pallet-out. This allows a high efficient use of space and reduces pick times through simplified stock accessibility.

Narrow Aisle Racking

Narrow aisle racking systems efficiently utilise the available height and floor space of the warehouse. They often combine picking and bulk locations under the control of the warehouse systems. The management by computers and radio data terminals of narrow isle trucks, cranes and order pickers, working between high stacks of pallet racking, now provides and efficient storage and handling system in many warehouse operations.

Just look at how storage system can do wonders!
storage is improtant for many reasons, some are:

• Server capabilities are maximized
• Open floor space is increased
• Management costs are lowered

You will have a clear view of all the stocks and they can be catogorised.

in case of fire, there are space to run and escape.

Warehosue Racking & Industrial Shelving

A system for non-palletized cartons.

The system features 26-foot-high frames with 13 beam/shelf levels. Each beam level is fitted with waterfall-style wire-mesh decks. These create a shelf membrane ideal for storing even the smallest cartons.

Company like UPS adopt this shelving as they have alot of boxes/ cartons in small packs. this ystem enables storage to be neat and will not drop cartons with the wire mesh attached.

Structural steel aisle guides and full-width structural steel entry guides protect the frames. These features also help guide the warehouse operator into the aisles. The system also features a custom coloured racking and beam location labeling system. This ease the process of locating the carton, and provides a clear view of products.

Double Deep Pallet Rack

Double deep racking is created by placing 2 double-sided runs together. Pallets are stored 2 deep and are accessed using special trucks with pantograph or telescopic forks. Using a deep reach lift truck, the operator places the back pallet into the system first, then places another pallet in front of it. While selectivity has been reduced by one-half over standard pallet rack, twice as many pallets are stored for a given number of aisles. This increases productive use of floor space about 60% to 65%. The system requires the use of a special reach truck with either dual pantograph or slide fork attachments. Truck lift heights are limited by load to about 9 metres. Upper levels can be fitted with guide rails to assist forklift drivers in locating pallets, they also help reduce fork truck operator error and accidental impact damage.

The advantage of two-deep rack facings (perpendicular to the aisle) is that fewer aisles are needed. In most cases, a 50 percent aisle space saving is achieved versus single-deep selective rack. However, we cannot assume that a 50 percent true space savings will be achieved because we can only anticipate a 70 to 75 percent utilization of the available openings (due to honeycombing). (80 to 85 percent utilization ia common for single deep racking.)

Double-deep racks are typically used when the storage requirements for a SKU is five pallets or greater and when product is received and picked frequently in multiples of two pallets. (Assigning SKUs with only a single pallet on-hand to double-deep racking is nonsensical because one of the two positions in a facing is automatically wasted.)

Introduction to APR..

See the picture on the left, it is the most popular form of storage for palletised goods in warehouse! It is widely specified in almost every industry and easily adapts to the vast and complex range of products needing to be stored. We call it Adjustable Pallet Racking(APR). It is cost-effective as the beam height is adjustable for different pallet load heights. It also can be used for non-palletised loads such as drums.