Pallet racking systems are a core part of any warehouse setup, and amongst them, push back racking systems stand out as an efficient and versatile solution.
In this comprehensive guide we’ll explore push back racking systems, providing insight into their functionality, benefits, components, and practical aspects of design, installation, safety, and maintenance.
Understanding Push Back Racking
Push back racking systems are an innovative storage solution designed for high-density warehousing. These systems provide deep-lane storage; reducing aisle space while maximising storage density.
Let’s take a more detailed look at how push back racking systems work:
The Structure
A push back racking system consists of a static rack structure, inclined rails, and a series of nested carts. The racks are traditionally built two to five pallets deep, although deeper systems can be created depending on warehouse needs. Each level of the rack can hold a different product, providing excellent versatility and adaptability for various types of inventory.
Loading
When loading pallets onto the system, the forklift operator places the first pallet on the top cart. When a second pallet is loaded, it pushes the first pallet back, "nesting" on top of the second cart. This process continues as more pallets are added, each pushing the previous pallet further back into the system.
Operation
The operation of push back racking systems is based on the Last-In, First-Out (LIFO) principle. This means that the last pallet loaded onto the lane will be the first one taken out. This operation makes it particularly suited for storing multiple pallets of the same SKU and for items that are not date-sensitive.
Unloading
When a pallet is unloaded, the forklift operator removes the front pallet, allowing the remaining pallets to roll forward due to the inclined rails' gravitational force. This mechanism ensures that the front of the lane is always stocked, reducing the time required for forklift operators to access the inventory.
Safety Mechanisms
Each cart within the push back racking system has a safety feature that prevents the pallets from being pushed off the back of the rack. This, along with proper training and compliance with safety standards, helps ensure a safe and efficient warehouse environment.
Uses & Benefits of Push Back Racking
Push back racking systems are optimal for storing medium-turnover goods and are advantageous in industries like food and beverage, retail, and distribution, where dense storage and efficient use of space is a necessity. They are particularly suited for storing multiple pallets of the same SKU.
The main benefits of push back racking systems can be broken down into the following key areas:
Space Utilisation
Push back racking systems optimise warehouse space by storing pallets two to five deep while reducing aisle space. This high-density storage system significantly increases the warehouse's storage capacity, making it a preferred choice for warehouses with limited space.
Inventory Management
Push back racking systems work on a Last-In, First-Out (LIFO) system. This is particularly beneficial for goods with longer shelf lives or non-perishable goods, allowing for easier inventory control and reducing the chances of goods becoming obsolete in storage.
Efficiency & Productivity
With the ability to store multiple pallets in a single lane, push back racking systems streamline operations by reducing the time taken to load and unload pallets. This improves warehouse efficiency and productivity by reducing forklift travel times.
Damage Control
Push back racking systems help to decrease the chance of rack damage caused by forklifts because operators do not need to enter the racking. This can lead to a significant reduction in maintenance costs and increase the lifespan of the racking system.
Versatility
Each level of a push back racking system can accommodate a different product, offering high versatility in terms of stock keeping unit (SKU) storage. This flexibility allows warehouses to manage a varied inventory effectively.
Accessibility
While offering high-density storage, push back racking systems still allow direct access to different lanes, unlike drive-in systems. This balance between storage density and accessibility adds to the overall operational efficiency.
Push Back Racking Components & Configuration
Push back racking systems comprise several components: the frame, incline rails, and nested carts. The frame provides the structure, while the rails, set at a gentle incline, guide and retain the carts. Each cart is designed to hold a single pallet and to sit neatly on top of the cart in front when pushed back.
A key strength of push back racking systems lies in their flexibility and configurability. The depth, height, and layout of these systems can be tailored to fit specific warehouse requirements, space constraints, and inventory characteristics.
Let's delve into the main configuration options:
Depth of Lanes
One of the primary configuration options for a push back system is the depth of the lanes, determined by the number of pallets stored in a single row. This could range from 2 to 5 pallets deep, with some systems accommodating even more.
A two-deep configuration may be suitable for businesses with a high number of different SKUs, offering a balance between density and selectivity. On the other hand, a five-deep system (or deeper) maximises storage density and could be ideal for businesses with large quantities of the same SKU, such as bulk food or beverage producers.
Height of Systems
The height of a push back racking system is typically dictated by the height of the warehouse and the reach capability of the material handling equipment. Multiple levels of push back racks can be installed, each level potentially storing a different product.
Layout
The layout of push back racking systems within the warehouse can also vary. They can be installed in back-to-back rows for maximum density, or as single rows along walls to utilise space efficiently. The chosen layout often depends on factors like the shape and size of the warehouse, the need for aisle space, and the flow of operations.
Pallet and Cart Size
Push back racking systems can also be configured based on the size of the pallets and loads to be stored. This may influence the design of the carts, the spacing of the rails, and the overall structure of the rack. For instance, warehouses storing oversized or irregular-shaped items might require specially designed carts and larger spacing between rails.
Designing & Installing A Push Back System
Choosing and installing the right push back system involves assessing your warehouse's space, inventory characteristics, and operational needs. Once the most suitable design and layout are determined, installation involves setting up the frame, securing the rails, and placing the carts.
The successful implementation of a push back racking system depends largely on thorough planning and expert installation. Installation should always be carried out by experienced professionals, as proper alignment of components is crucial for safe and efficient operation.
Broadly speaking, the design and installation process involves the following steps:
Assessing Warehouse Space
The first step involves assessing the available warehouse space. This includes not just the floor space, but also the vertical space that can be used for stacking. The design should also take into consideration the need for aisles, access points, and safety zones.
Evaluating Inventory Needs
The type and volume of inventory to be stored greatly influence the design of the push back system. Factors such as pallet size, weight, and the number of different SKUs all play a role in determining the configuration of the system.
Determining System Configuration
As discussed previously, the configuration of a push back system can be customised to specific needs. This includes the depth of lanes (how many pallets deep), the number of levels, and the layout within the warehouse. The chosen configuration should offer the best balance of storage density, selectivity, and operational efficiency for the business.
Selecting Material Handling Equipment
The type of forklift or other material handling equipment in use will also affect the design of the push back system. The equipment needs to be able to safely reach and handle the loads on all levels of the system.
Installation
Once the design has been finalised, the installation process can begin. This should always be carried out by trained professionals to ensure safety and compliance with regulations. Installation includes erecting the rack structure, installing the rails and carts, and testing the system to ensure it operates smoothly.
Sign Off & Handover
When the new push back racking system has been thoroughly tested to ensure it is in full working order, and any snagging has been completed, it’s time for the final handover to the client. This is probably the most exciting step in the process, as the system can now start being put to good use.
Safety & Maintenance For Push Back Racking
Push back systems, like all racking systems, require regular inspections and maintenance. Rails should be kept free of debris, and carts should be regularly inspected for wear and tear.
Safety is a priority in the use of push back racking. Adequate training should be provided to forklift operators to prevent accidents and mishandling. Loads should be evenly distributed and never exceed the system's designated weight capacity.
Push Back Racking: Regulatory Compliance & Standards
In the United Kingdom, push back racking systems, like all warehouse racking systems, must adhere to strict regulations and standards to ensure safety and efficacy.
The Provision and Use of Work Equipment Regulations 1998 (PUWER) mandates that all work equipment is maintained in a safe condition and suitable for its intended purpose. Additionally, the Health and Safety at Work Act 1974 outlines the obligations of employers to ensure the health, safety, and welfare of their employees.
In terms of specific standards for pallet racking, the British Standard BS EN 15629:2008 and BS EN 15620:2008 provide the specification for the design, testing, and utilisation of industrial pallet racking.
Regular rack inspections and maintenance are essential to ensure ongoing compliance and to maintain a safe and efficient working environment.
Comparing Push Back Racking to Other Racking Systems
While push back racking offers numerous benefits, understanding how it compares to other racking systems can be crucial in decision-making.
Traditional selective pallet racking, for example, offers high accessibility but lacks the storage density of push back racking.
Drive-in racking or drive-through systems are also high-density but lack the selectivity of push back systems.
On the other hand, pallet flow racking operates on a First-In, First-Out (FIFO) basis, which may be more suitable for perishable goods compared to the LIFO operation of push back racking.
Cost-Efficiency of Push Back Racking Systems
Push back racking systems are a capital investment that can yield significant cost savings over time. The high storage density reduces the need for aisle space, allowing for a greater number of pallets to be stored per square metre.
If you’re looking for a way to increase the storage density of a warehouse, then push-back ranking is an excellent option.
As well as increasing the quantity of goods that can be stored in a space, the reduction in forklift travel distances that push back ranking delivers can decrease operating costs, improve efficiency, and minimise the risk of damage to goods and racking, further contributing to cost savings.
Overall, the combination of high density and selective storage, and potential to reduce costs in other areas of operation, means that when used for suitable applications, push back racking can deliver a great ROI and be highly cost efficient.
Future Trends in Push Back Racking Systems
As industries evolve, warehouse storage solutions are also set to adapt to new trends and technological advancements. Here are a few key trends shaping the future of push back racking systems:
Greater Integration with Automation
Automation is transforming every facet of warehousing, and push back racking systems are no exception. We can expect to see a more significant integration of automated storage and retrieval systems (AS/RS) in push back racking.
Automated forklifts and robots, equipped with advanced sensors, could be used to load and unload pallets, minimising human error, increasing efficiency, and further reducing the risk of damage to goods and racking systems.
Internet of Things (IoT) Enabled Systems
The use of IoT in warehousing is growing, offering the potential for real-time inventory management, predictive maintenance, and enhanced data analysis.
IoT-enabled pallets and carts could provide instant updates on the status and location of goods, while sensors could monitor the condition of the racking system and predict maintenance needs before they become critical issues.
Advanced Material Technologies
As material science progresses, we may see the development of lighter, stronger, and more durable materials used in the construction of push back racking systems.
Over the coming decades this could allow for taller, deeper racking systems, increasing storage density even further. These advanced materials might provide better resistance to wear and tear, extending the lifespan of the racking system.
Environmentally Friendly Designs
As sustainability becomes a higher priority for most businesses, we might see a greater emphasis on environmentally friendly designs in push back racking systems.
This could include the use of recycled or sustainable materials in construction, designs that minimise energy use (such as reducing the need for lighting or temperature control), and systems that can be easily repurposed or recycled at the end of their life cycle.
Find Out How Push Back Racking Can Benefit Your Business
Push back racking systems offer a multitude of benefits that make them a preferred choice for businesses looking to optimise their warehouse storage.
- Excellent space utilisation
- Efficient inventory management
- Improved operational efficiency
- Damage control
- Storage versatility
- Balanced accessibility
View Push Back Racking Solutions
At Avanta, we’re a UK leader in the area of pallet racking design and installation, with significant experience and a deep understanding of warehousing and workspace requirements within a broad range of industries.
Whether you're looking for a push back racking system, other types of racking or storage solutions, or are interested in expanding your floor space using mezzanine levels, we deliver bespoke solutions that cater specifically to your business needs.
Our team works closely with clients throughout the UK, ensuring a seamless, end-to-end service from initial consultation and design, through to installation and aftercare. We are committed to not only delivering high-quality warehouse solutions but also ensuring they align perfectly with your business operations, leading to improved efficiency and cost-effectiveness.
To explore the potential of push back racking systems for your organisation, contact us to learn more about how we can help revolutionise your warehouse operations.
Push Back Racking FAQs
Q: What is the weight limit for push back racking?
A: The weight limit for push back racking systems varies depending on the design and materials used. However, each pallet position can typically hold from 750 to 1,200 kilograms. Always consult with your racking provider to understand the specific weight limit for your system.
Q: How tall is a push back racking system?
A: The height of a push back racking system depends on several factors including the warehouse's ceiling height, the lift height of the forklifts, and safety regulations. In general, they can be built as tall as your facility and equipment allow.
Q: What is the lifespan of a push back racking system?
A: With proper maintenance and care, a push back racking system can last for over 15 years. Regular inspections and prompt repairs can further extend the lifespan of these systems.
Q: What are the main advantages of push back racking?
A: Push back racking offers many advantages, including excellent space utilisation, efficient inventory management, improved operational efficiency, versatility, and reduced damage to pallets and racks.
Q: What are the main disadvantages of push back racking?
A: The main disadvantage of push back racking is that it operates on a Last-In, First-Out (LIFO) basis, which may not be suitable for all types of inventory, especially for goods with a short shelf life. Additionally, initial investment costs for these systems can be higher compared to other racking types.
Q: What is push back racking typically used for?
A: Push back racking is typically used for high-density storage of multiple pallets of the same SKU. It is widely used in industries such as food and beverage, retail, and distribution, particularly where space maximisation is a priority.
Q: Do push back racking systems need specialist forklifts?
A: Push back racking systems do not necessarily require specialist forklifts, but the forklifts need to have the necessary lift height and load capacity for safe operation. Also, operators should be trained in the correct loading and unloading procedures for push back systems to ensure safety and efficiency.