Top 7 Mistakes People Make with Pallet Racking Industrial Systems

Introduction to Pallet Racking Industrial Systems

Industrial pallet racking is a heavy-duty shelving system used in large storage areas, like warehouses. It’s designed to hold rows of pallets (stacked materials) on strong metal shelves, keeping everything organized and easy to access.

This setup makes a huge difference! With pallet racking, workers can quickly grab what they need without sorting through piles of boxes, helping everything run smoothly and safely.

Pallet racking industrial systems are designed with multiple levels of shelving that allow forklifts to reach items stored higher up.

Types of Industrial Pallet Racking

1. Selective Racking

   a. Common and simple! Shelves are set up in single rows, so every pallet is easy to reach. Great for warehouses that need to access items frequently.

2. Drive-In Racking
   

   a. Forklifts drive directly into the rack to get to the pallets. It’s best for storing a lot of the same item but isn’t ideal if you need to grab individual pallets quickly.

3. Push-Back Racking
   

   a. new pallets push older ones back on rolling shelves, which makes good use of space. It’s handy for items that don’t need to be accessed often.

4. Pallet Flow Racking
   

   a. This type works like a conveyor belt: load pallets on one side, and they slide to the other for easy access. It’s perfect for fast-moving inventory.

5. Cantilever Racking
   

   a. Used for long or bulky items, like pipes or lumber. It has “arms” instead of full shelves, making it easy to store these oversized items.

Why Pallet Racking Industrial Is Important for Warehouses

1. Makes the Most of Space

   Pallet racking helps you use vertical space in your warehouse, letting you store more pallets without taking up extra room.

2. Easier to Find Items

   With organized pallet racking industrial, it’s simpler to find and track products. Every pallet has a spot, making it faster to locate items.

3. Forklift-Friendly

   These racking systems are made for forklifts. They make it easier and quicker to load and unload pallets, saving time and effort.

4. Keeps Things Safe

   Well-installed pallet racking industrial systems help keep pallets stable and prevent them from falling, making the warehouse safer.

5. Grows with Your Business

   As your business grows, you can easily add more racking to your warehouse. Pallet racking industrial systems are flexible and can expand when you need more space.

What Is the Difference Between Pallet Racking and Shelving?

Feature	Pallet Racking	Shelving
Purpose	Stores large items on pallets, ideal for heavy goods moved by forklifts	Stores smaller, lighter items placed manually on shelves
Weight Capacity	Can hold much heavier loads (thousands of pounds)	Best for lighter items with lower weight limits
Storage Method	Items are placed on pallets, moved by forklifts, great for big storage areas	Items are placed directly on shelves, often manually accessed
Space Efficiency	Uses vertical space, ideal for large warehouses	Takes up more horizontal space, better for offices or small retail spaces

 

How to Choose the Right Pallet Racking Industrial System:

1. Know What You’re Storing:

   1. Decide if your products are heavy, light, or oddly shaped. This will help you understand what type of racking system you need. For example, selective pallet racking works well for standard pallets, while drive-in racking saves space for high-density storage.

2. Check Weight Capacity:

   1. Different racking systems hold different amounts of weight. Standard racking holds up to 1,500 to 3,000 pounds per pallet. If you need something stronger, look into systems like drive-in racking designed for heavy loads.

3. Measure Your Space:

   1. Look at your warehouse layout. Some systems need more aisle space to fit forklifts, while others, like drive-thru racking, can store more in the same area, saving up to 60% of your space.

4. Forklift Access:

   1. Make sure there’s enough room for forklifts to move. Usually, aisles need to be around 8-10 feet wide depending on the system you choose.

5. Safety Features:

   1. Check that your system has strong load beams and other safety measures. Regular inspections are important to avoid accidents—about 5-10% of warehouse accidents happen due to racking issues.
   2. Load beams are the horizontal bars in pallet racking systems that hold and support the weight of pallets. They keep everything in place and prevent collapse by bearing the weight of stored goods.

6. Balance Cost and Long-Term Benefits:

   1. Cheaper systems can be tempting; a better system can increase your storage space by 30% or more, saving you money in the long run.

Read more: Industrial Racking: Does Your Business Need It? 

How to Maintain Pallet Racking Industrial Systems

1. Regular Inspections: Check your racking system regularly for damage, like beams that may have bent or twisted. This can happen when too much weight is placed on them or if they’re hit by a forklift. Bent beams can weaken the structure, making it unsafe. Inspections should be done at least once a month to catch problems early.

2. Load Distribution: Make sure the weight is evenly spread across each shelf. Overloading one side can cause the racks to become unstable or damaged.

3. Clean the Area: Keep the racking system and the surrounding area clean. Dust, debris, or spills can affect the racks and forklifts, making them less safe and efficient.

4. Train Employees: Ensure your employees are trained to handle the racking system safely, especially when operating forklifts or placing heavy loads on the shelves.

5. Safety Features: Always check that safety features, like locking pins and barriers, are in place and working to protect the system and workers.

6. Quick Repairs: If any part of the racking system is damaged, repair it immediately, same goes for repairing forklifts. Small problems can quickly grow into bigger, more expensive ones if left unchecked.

Top Mistakes to Avoid with Pallet Racking Industrial Systems

1. Overloading the Racks:
   1. It’s tempting to load pallet racks with more weight than recommended, but this can lead to rack collapse or serious damage.
2. Improper Installation:
   1. Pallet racks need to be installed correctly to ensure their safety and efficiency. Improper installation contributes to 30% of racking-related failures, increasing the risk of accidents and product damage.
   1.  Avoid cutting corners on installation—use proper tools and hire qualified professionals if necessary.
3. Ignoring Regular Inspections:
   1. Pallet racking systems should be checked regularly for signs of wear and tear, like bent beams, loose bolts, or rust. Not inspecting your racks could double the likelihood of failure over time.
4. Not Considering Future Growth:
   1. When choosing a pallet racking system, think about the future of your business. A survey found that 65% of businesses regret not planning for future growth when they first set up their racking system.
5. Poor Layout Design:
   1. A common mistake is poor warehouse layout planning. Studies show that poor layout design can lead to a 20% inefficiency in workflow, impacting overall productivity. Ensure aisles are wide enough for easy forklift access and that storage locations are strategically organized for fast retrieval of goods.
6. Inadequate Training for Staff:
   1. Workers need to be trained in the proper use of pallet racking systems, including how to load and unload safely. Most of the warehouse accidents involve improper handling or lack of training.
7. Ignoring Safety Standards:
   1. Compliance with local safety standards is essential. Non-compliance can cost companies over $14.82 million in fines and penalties every year.
   2. Avoid cutting corners when it comes to safety regulations to prevent accidents and legal trouble.

Why Calculate Pallet Racking?

1. Make the Most of Your Space: Calculating pallet racking will help you use every inch of your warehouse, especially vertical space to store more items.
2. Keep It Safe: By calculating load limits, you avoid overloading the racks, so that the system is safe for your team.
3. Save Money: Good planning will save you from wasting money on extra racks or unused space.

How to Calculate Pallet Racking

1. Measure Your Space: Know the size of your warehouse—how tall, wide, and deep it is.
2. Decide on Rack Levels: Based on your warehouse height and forklift type, choose how many rack levels you need.
3. Check Weight Limits: Make sure your racks can hold the weight of the products you want to store.
4. Pick the Right Rack Layout: Decide between single-deep or double-deep racks depending on your needs for space and access.
5. Leave Room for Aisles: Forklifts should have enough space to move around between racks easily.

Why Choose MDS Industrial for Your Racking Needs?

Running a warehouse can be a challenge, especially when it comes to making the most of your space.

That’s where MDS Industrial comes in. We offer expert racking services to help you maximize your storage, improve efficiency, and keep everything running smoothly.

Here’s what we can do for you:

1. Racking Relevels – Getting More Out of Your Space

Over time, pallet racks can shift or settle, which means you’re not using your space as efficiently as possible.

Our racking releveling service helps fix that by repositioning your racks to open up more room.

This can make a huge difference, especially when working with limited space. It’s a smart way to boost productivity without buying new racks.

2. Rack Installations – Custom Fit for Your Warehouse

When it comes to rack installations, we don’t just put up shelves. We take a look at your whole warehouse and figure out the best layout for your space.

If you’re looking to install brand-new racks or give your old ones a second life with refurbished options, we work with you to find the right solution that fits your space and budget.

It’s all about giving you the most storage possible while keeping things simple and safe.

3. Demo Existing Racking – Clear Out the Old, Bring in the New

If your old racking is no longer doing the job, we can help by carefully removing and disposing of it for you.

This clears up space and makes room for a more efficient system that works better for your current needs.

4. Rack Repair Kits – Fix What’s Broken Without Replacing Everything

If your racks are in need of minor repairs, we can help with our rack repair kits.

Sometimes all it takes is fixing a few bent beams or tightening loose bolts.

Instead of buying all new racks, our repair kits help you save money while keeping your system in good shape and running safely.

Why MDS Industrial?

• Experience: We’ve been in the business long enough to know what works and what doesn’t. Our team knows how to handle all types of racking systems—old and new.
• Customized Solutions: We understand every business is different. Every service is customized to meet your warehouse’s specific needs.
• Safety: We put safety first. Our services are designed to keep your workers and your inventory safe.
• Cost-Effective: We offer affordable options, so you get the best value for your money without compromising on quality.

Ready to make your warehouse work better for you? Get in touch with MDS Industrial today. We’re here to help!