What is Drive-in Racking System?

The key principle in warehouse design is maximizing the utilization of space effectively.

Improving the selection of shelves and racks is the first crucial step in optimizing warehouse usage. This requires a thorough grasp of warehouse layout and identifying areas for enhancement, as well as understanding where adjustments can be made to achieve optimal efficiency.

Types of Drive-in Racking Systems

Various types of pallet racking systems are available, with some offering higher storage density and others facilitating efficient product movement and picking. Typically, there’s an inverse correlation between product storage density and movement, meaning higher storage density can lead to slower product movement, and vice versa. Two commonly used pallet rack systems prioritizing storage density are drive-in and drive-through racks.

Drive-in pallet racks, where loads are stored sequentially, are ideal for low turnover inventory, similar SKUs, and full pallet load selection due to limited load access. Loads are arranged with the first pallet stored being the last pallet out (FILO), and vice versa.

To load or unload pallets from drive-in racks, operators must enter the storage lane and reach the back face of the storage bay. This system optimizes space efficiency by eliminating aisles between rack rows, allowing more pallets per square foot for storage.

In contrast, drive-through racks feature two loading/unloading aisles accessible from either side, enabling faster stock rotation as pallets can be loaded and unloaded from opposite sides. Drive-through racks facilitate first-in, first-out (FIFO) inventory management, but require more space due to the dual aisles compared to drive-in systems.

How Does a Drive-in Racking System Work?

Forklift operators position pallets of goods onto rails located at the rear of the system. Subsequently, new products are loaded in front of older ones.

Given that only one side is accessible for loading or unloading, the back of the system can be positioned against a wall. Alternatively, if aisles are present on both sides, the horizontal supports can be placed in the center of the system to enable dual-sided access, albeit at the cost of some space due to the access aisles.

Advantages of Drive-in Racking

• Enhanced Storage Efficiency: Drive-in pallet racking systems generally offer increased storage density compared to traditional selective rack systems. This is achieved by storing pallets closer together with fewer aisles required, as only one aisle for retrieval is needed instead of the usual two aisles.
• Cost-Effectiveness: Drive-in pallet racking systems prove cost-effective due to their ability to maximize storage density, leading to more efficient utilization of floor space. Furthermore, these systems can be tailored to meet the specific requirements of businesses.
• Customization Possibilities: While transforming a drive-in design into a drive-through rack is one potential modification, suppliers present various alternative options. These include angled shelves enabling pallets to move towards the front for loading and unloading, as well as combination systems incorporating flow-through or push-back racks. Such systems are often integrated with other storage solutions like wall-mounted racks or drive-through racks.

Disadvantages of Drive-in Racking

• Drive-in racks may not be appropriate for all product types due to their adherence to a last-in, first-out inventory system.
• There is an increased risk of forklift damage to drive-in racks due to the high volume of traffic and tight spacing within the system.
• Inadequate management can result in more frequent occurrences of lost products within drive-in racks.
• Accessing pallets located beyond the front of the rack may necessitate double handling within drive-in rack systems.
• Drive-in rack systems are vulnerable to honeycombing, where operators neglect to deposit loads at the rear of the racking system, resulting in dead storage space.

Drive-in Racking Dimensions

In drive-in rack systems, the pallets rely on the outer 3 inches of the rails for support, making the pallet crucial for load stability. Therefore, having sturdy pallets is essential for effective use of drive-in applications. Drive-in rack dimensions are typically tailored to accommodate one specific pallet size, commonly 40 inches wide like GMA pallets. The space between the vertical legs of the pallet guide angles is set at 42 inches, with the pallet guide rails measuring three inches wide. This arrangement allows for a one-inch gap on each side of the pallet to ensure secure placement. Any deviation from these dimensions could result in instability, with smaller pallets potentially falling if not centered perfectly, and larger ones risking damage to the rack structure.

When planning a drive-in rack system, factors such as facility height and width, along with pallet type and size, must be carefully considered. Due to their ability to maximize storage density, drive-in applications often involve taller configurations. Common upright heights for drive-in racks typically range from 16 to 20 feet, although shorter options are also available.

Drive-in Racking Structure

The fundamental elements of a drive-in racking system include uprights, upright frames, rails, horizontal beams, arms, and row spacers. Below, we will delve into each component in more detail.

 

• Upper Longitudinal Beam: The upper longitudinal beam serves to connect the frames in the upper section, enhancing the structure’s stability and coherence. These beams are essential in all compact racking aisles.
• Horizontal Brace: This conventional selective rack beam reinforces the compact structure and contributes to its overall stability. Positioned at the top and back of the drive-in rack, the horizontal brace is crucial for lateral stability.
• Frame: The frame forms the backbone of a compact drive-in rack, comprising two uprights, corresponding diagonals, baseplates, and anchors. Its primary function is to support the load and maintain structural integrity.
• Forklift Guide Rail: While optional, forklift guide rails play a critical role in drive-in and drive-through systems. Constructed from robust steel, these rails extend the depth of the aisle, safeguarding the upright frames within the structure. They also serve to protect the forklift from potential impacts and facilitate smoother and safer operations by separating it from the drive-in compact racking.
• Frame and Upright Protection: These protectors shield the installation from damage that may occur when forklifts enter and exit the system, enhancing overall safety.
• Welded Base Plate: Specially designed for frames handling heavy loads, welded baseplates offer added strength and durability. Constructed from welded steel, they undergo rigorous testing to withstand demanding conditions.
• Upright: Single upright posts can be used alongside frames to extend the depth of the system.
• Pallet Rails: The pallet guidance system ensures accurate pallet placement during loading and unloading, safeguarding the structure from potential damage.
• Pallet Beam or Support Rail: These horizontal profiles provide support for the pallets on each level of the drive-in racking system. Typically selective rack beams, they are secured to the upright using conventional endplates.
• Arms: Attached to the upright, arms support the rails on each level, thereby supporting the pallets.
• Pallet Backstop: An essential feature in any warehouse or distribution center, pallet backstops prevent pallets from falling at the back of the aisle due to improper handling, promoting a safer work environment and reducing the risk of product damage

How to Tell if a Drive-in Racking System is Right for you

Before committing to a drive-in pallet rack system, several factors warrant consideration.

Firstly, it’s crucial to ascertain whether your product aligns with the Last-In, First-Out (LIFO) storage method and if your operational requirements necessitate minimal order picking. Goods with time constraints, perishable items, and delicate loads may not be suitable for this system. Additionally, consistent pallet sizing and load-bearing capacity are essential, along with adherence to operational protocols to prevent honeycombing.

Furthermore, the cost of the system requires careful evaluation. Drive-in racks typically incur higher expenses compared to alternative storage systems. Therefore, it’s imperative to assess whether the increased storage density offered by this system justifies the investment.

FAQ’s

What factors should I consider before investing in a drive-in pallet rack system?

Before committing to a drive-in pallet rack system, several factors should be carefully evaluated. Firstly, determine if your products are suitable for Last-In, First-Out (LIFO) storage and if your operations require minimal order picking. Additionally, ensure your pallets are of consistent size and capable of supporting the load. It’s also crucial to maintain operational discipline to prevent honeycombing, which can affect system efficiency.

Are there any products unsuitable for drive-in rack systems?

Yes, certain products may not be well-suited for drive-in rack systems. Time-sensitive items, perishable goods, and fragile loads are examples. Drive-in racks are typically best for low turnover inventory with similar SKUs and full pallet load selection.

How can I determine if a drive-in racking system is suitable for my warehouse?

To assess the suitability of a drive-in pallet rack system for your warehouse, consider your product compatibility with LIFO storage and operational requirements. Evaluate the consistency of pallet sizes and weigh the cost-effectiveness of the system against alternative storage solutions. By carefully analyzing these factors, you can make an informed decision about implementing a drive-in racking system in your warehouse.

Conclusion

Optimizing warehouse design involves maximizing space while ensuring operational efficiency. Selecting suitable racking systems like drive-in racks is crucial. While these systems offer increased storage density and cost-effectiveness, they require careful management to avoid drawbacks. Assessing product compatibility, operational needs, and cost-effectiveness is essential. With proper planning, drive-in racking systems can greatly enhance storage efficiency and streamline warehouse operations.