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How to store more product in my warehouse?

21 Jun, 2023
Maximise warehouse storage with strategic solutions tailored to your needs. Whether it's optimising for fast-moving products or accommodating unique item sizes, our guide offers innovative approaches to utilize every inch of space efficiently. For detailed strategies on enhancing your warehouse's storage capacity, including practical tips on various racking systems, visit the full article

If you’re struggling to find space to store all your products, don’t worry – you’re not alone.
With so many storage options available, it’s easy to feel overwhelmed and unsure where to start. That’s why Total Racking Systems are here to help!

The key to maximising your warehouse space is understanding your current storage needs. Look at how many pallets are currently in storage for each product line or type, as this will help you design a storage system that works best for you.

You have probably heard of Pareto’s Principle, which tells us that 80% of our outgoing product comes from just 20% of our product lines, which means not all product lines are to be stored or treated equally. It’s really important to prioritise storage and accessibility to the 20% of your product lines that are fast-moving items. Store them where they are easy to access, like close to your dispatch and packing zones and keep those product lines in stock to avoid any potential shortages. By doing so, you can ensure that your staff have quick and easy access to the products they need while reducing the risk of overstocking slow-moving items that take up valuable space in your warehouse.

But you can’t forget about the other products! By storing them in less accessible areas or on higher levels of your racking, you can free up valuable space. Check out our helpful tips and ideas below for more advice on how to store your different product lines.


Your main options are:

Bulk stacking

Bulk stacking requires no racking systems.

It is suitable if you have:

  • A few differing product lines
  • Many pallets of each product line
  • Large warehouse floor space available
  • It is ideal for light products as the product requires stacking – heavy products can cause the crushing of pallets underneath.

Although bulk stacking can be economical, you are limited by how high you can safely stack the pallets on top of one another. This means that valuable vertical spare is not utilised.

The disadvantage of bulk stacking is wasted vertical space that could be used for storage and less access to products.

Drive-in Racking

Drive-in racking works on a Last-in, last-out (LILO) inventory system.

It is suitable if you have:

  • Products with a long shelf life that will not deteriorate or perish over a longer period
  • Multiple pallets of the same product line

Drive-in pallet racking works on a Last-in, last-out (LILO) inventory method and enables you to use both your warehouse’s vertical height and floor space effectively, making it a very economical solution. You can store many pallets of the same product lines.

Pallet flow Racking

Pallet flow racking works on a First in, first out (FIFO) inventory system.

Pallet flow racking is suitable if you have the following:

  • Products with a short shelf life with expiration dates or “best before” dates.

If your products have expiration dates or “best before” dates, Pallet Flow Racking is ideal for your warehouse’s storage needs. It operates on a First-In, First-Out principle and allows the oldest pallet to be at the front for stock picking. This system best uses your warehouse’s vertical and floor space.

How to Store Medium/Slower-Moving Products (SKUs) or Fast moving but smaller product lines (The 80%)

Selective Pallet Racking

Selective pallet racking is the most basic form of pallet racking and the most popular. It is cost-effective and versatile, and pallets can be accessed by different forklifts at any entry point.

Selective racking is best if you need:

  • An economical and versatile system where all products have 100% accessibility
  • Have products with expiration dates or products you need to access quickly
  • Need to see all your palletised products easily

This racking system takes up more space per pallet than a pallet flow system.

Double-Deep Racking

With double-deep racking, you can reduce the amount and size of aisles, thereby utilising your floor space optimally. Although this system doesn’t allow immediate access to all

Double deep racking is best if you:

  • Need to reduce aisle size and number of aisles to better utilise your floor space
  • Don’t need immediate access to all pallets as it operates on a FILO (First-in, Last-Out) principle
  • Have a special forklift with an extension arm or a deep-reach lift truck to place pallets in the deeper position.

Double deep racking allows two selective racks to be pushed together, doubling the storage area’s depth.

Push Back Racking

Pushback racking is a storage system that allows multiple pallets of goods to be stored in a single bay, with the pallets being loaded and placed on wheeled carts that roll on inclined rails. When a new pallet is loaded onto the racking, it pushes the pre-existing pallets further back, hence the name ‘push back’.

Pushback racking is best if you:

  • Don’t have products with expiry dates
  • Need high density storage and greater access to goods than block stacking
  • Require LIFO (last-in, first-out) inventory management, as the most recently loaded pallets can be accessed first.
  • Have a special forklift with an extension arm or a deep-reach lift truck to place pallets in the deeper position.

Push-back racking is designed to provide excellent use of available space and reduce the number of aisles required within the warehouse. By using inclined rails and wheeled carts, workers can easily load and unload pallets without moving them around or taking them down from high shelves. This makes push-back racking a safe and efficient way to store palletized products, particularly when dealing with medium-moving products.

The key to maximising your warehouse space is understanding your current storage needs, prioritising storage and accessibility to the fastest-moving items and finding the right racking system to fit your unique requirements.

Total Racking Systems can help you navigate the various options available, from bulk stacking to drive-in, pallet flow, selective pallet, double-deep and push-back racking. By carefully considering each system in relation to your business’s specific needs, you can make an informed decision that maximises space utilisation and increases efficiency. Remember that not all product lines are created equal, and prioritising access to fast-moving items is key. With the right storage system, you can ensure your staff have quick and easy access to the products they need while reducing the risk of overstocking slow-moving items. At Total Racking Systems, we’re here to help you find the best storage solution for your business. Contact us today to learn more about our racking systems and how they can help you optimise your warehouse space.

Need to Store Products that are not suited for Standard Pallet Racking?

The above storage and racking systems are some of the most common and popular among our clients; you have other options available. No two clients will have the same storage needs so that the systems can be tailored to your needs.

Cantilever Racking

Best if you:

  • Need to store extra long, oddly shaped or bulky items such as timber lengths, steel lengths, extrusion, pipes, sheet metal, board packs, etc.

Cantilever racking is easily customised to your requirements: rows of uprights can be any length required. The cantilever arms can be modified flexibly for stored goods with different heights and loading requirements.

Warehouse Mezzanine Floors

Best if you:

  • We have a lot of wasted vertical air space and would like to add a second floor for additional storage or office space without the hassle of council approvals & building works.
  • Would like to take the floor with you if you ever move – our mezzanines can be designed so you can dismantle & re-install at your new location.

Mezzanines can have a multitude of uses and can at least double your available floor space.

You can store products in your warehouse in many different ways, but not all are right for your operations. If you need help designing a complete storage solution to suit your product lines & warehouse areas, we’d love to hear from you.

Call 1300 301 144 or email Total Racking Systems to speak to an expert in space today!

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