What Is Double Deep Pallet Rack?

Double Deep Pallet Rack is essentially selective pallet racking with a doubled stacking configuration. It involves placing a front pallet and a rear pallet, with access to the rear pallet facilitated by a deep reach truck forklift capable of extending to reach the back pallet position.

 

What is Double Deep Pallet Rack

The Double Deep Pallet Rack is a high-density racking system designed to maximize storage capacity in warehouses. By reducing the number of aisles needed, it significantly increases storage density, making it a valuable solution for warehouses facing space constraints.

This system comprises two standard selective rack bays positioned back-to-back, accessible from one side. Each bay accommodates a front pallet and a back pallet.

Loading the double deep racks involves the use of a deep reach lift truck. The forklift driver maneuvers up to the racks, and the pantograph reach truck extends to place the load in the back pallet position. The front pallet is then loaded last, allowing the forklift to easily position it in the front.

Components of Double Deep Racks

Pallet Rack Upright Frames

In a double deep rack system, pallet rack upright frames serve as the support structure from which the beams are suspended, providing vertical stability. The depth of the uprights varies depending on the size of the pallets being used. Common depths for uprights in such systems are typically 42” and 48”, and they can be constructed from either structural steel or roll-formed steel.

Pallet Rack Beams

Pallet rack beams support the pallets and come with either a teardrop connection for roll-formed steel or a bolt-on connection for structural steel. These beams are adjustable on 2” centers and can be customized to accommodate specific loads.

Pallet Rack Wire Decks

Wire decks act as a safety measure to prevent pallets from slipping through the beams and can be tailored to support various loads.

Pallet Rack Row Spacers

Row spacers maintain rigidity in the system from front to back. For back-to-back double deep racks, a typical configuration includes a 42” frame, an 8” row spacer, another 42” frame, and a 12” row spacer.

Bull Nose Damage Protector

To safeguard against damage caused by forklift trucks with load wheels, particularly at the bottom of the upright frame, bull nose protectors can be added. Investing in these protectors can ultimately save money by reducing the need for repairs in the future.

Benefits of Double Deep Racks

Double deep pallet racking offers several benefits for warehouses looking to optimize storage space and efficiency. Here are some key advantages:

Increased Storage Density

The biggest advantage is the significant boost in storage capacity. By storing two pallets deep in each bay, you can nearly double your storage capacity compared to single deep selective racking systems. This translates to maximizing your existing warehouse footprint without needing to expand.

Reduced Floor Space Usage

Since double deep racking requires fewer aisles for accessing pallets, it frees up valuable floor space in your warehouse. This freed-up space can be used for additional storage needs, increased production areas, or improved employee flow.

Good Balance of Accessibility and Density

While not offering direct access to all pallets like single deep racking, double deep provides a good compromise between storage density and accessibility. You can still access the front pallet readily, and with proper inventory management, retrieval of the rear pallet isn’t overly complex.

Cost-Effective Solution

Compared to other high-density storage systems like drive-in racking, double deep racking offers a more cost-effective solution. The initial investment and ongoing maintenance costs are generally lower.

Adaptability

Double deep racking is often adaptable. Many systems allow for adjusting beam levels to accommodate different pallet heights, and some can even be converted to single deep racking if your needs change.

Drawbacks of Double Deep Racks

Double deep pallet racking offers increased storage density but comes with some drawbacks that need to be considered before implementation. Here are some key disadvantages:

Reduced Accessibility

Unlike single deep racking where every pallet is directly accessible, double deep requires special forklifts or attachments to reach the rear pallets. This can slow down picking and retrieval times, especially for frequently accessed items.

Safety Concerns

Double deep racking poses a higher risk for forklift accidents due to the limited visibility and maneuvering space required to reach rear pallets. Operators need specialized training and additional caution to navigate the aisles safely.

Limited Inventory Management

Double deep is best suited for a Last-In-First-Out (LIFO) inventory system, where the last pallet loaded is the first one retrieved. This might not be ideal for all products, especially those with expiration dates or requiring specific rotation.

Not ideal for all SKUs (Stock Keeping Units)

Double deep is less efficient for storing a wide variety of items or frequently accessed SKUs. It’s more suitable for warehouses with a limited number of high-volume, identical or similar products.

Storage Height Limitations

Safety regulations often restrict the maximum height for double deep pallet racking compared to single deep systems. This can limit the overall storage capacity in warehouses with high ceilings.

FAQ’s

What are the main components of a Double Deep Pallet Rack system?

The key components include pallet rack upright frames, pallet rack beams, pallet rack wire decks, pallet rack row spacers, and bull nose damage protectors.

How does the loading process work for double deep racks?

Loading involves the use of a deep reach lift truck. The forklift driver positions the truck in front of the racks, extending the pantograph reach to place the load on the back pallet position, followed by loading the front pallet last.

What are the benefits of utilizing double deep racks in a warehouse?

Double deep racking offers increased storage density, reduced floor space usage, a good balance of accessibility and density, cost-effectiveness, and adaptability to changing needs.

What are the drawbacks of implementing double deep racks?

Drawbacks include reduced accessibility, safety concerns due to limited visibility, suitability primarily for Last-In-First-Out (LIFO) inventory systems, limitations for storing a variety of items or frequently accessed SKUs, and storage height restrictions.

How do pallet rack upright frames contribute to the system?

Upright frames provide the vertical support structure from which beams are suspended, ensuring stability. They come in various depths to accommodate different pallet sizes and can be made of structural or roll-formed steel.

What is the purpose of pallet rack wire decks?

Wire decks act as a safety measure to prevent pallets from slipping through the beams and can be customized to support various loads.

How do bull nose damage protectors enhance the durability of double deep racks?

Bull nose protectors are added to safeguard against damage caused by forklift trucks, particularly at the bottom of upright frames, ultimately reducing repair costs and ensuring long-term durability.

Conclusion

The Double Deep Pallet Rack system offers a cost-effective solution for maximizing storage capacity in warehouses. Despite drawbacks like reduced accessibility, its benefits in terms of space efficiency and adaptability make it a valuable asset for warehouses managing growing inventory demands. With proper planning and maintenance, double deep racks can significantly enhance warehouse operations and optimize storage space utilization.