2-Deep Pallet Rack – How to Choose Between Push-Back vs Double-Deep

Stacking the Pros & Cons of Push-Back & Double-Deep for 2-Deep Pallet Rack

Get your snorkel, we’re going on a deep-dive into two-deep pallet rack storage – push-back vs. double-deep systems. What benefits, savings or hidden costs do you get with these high-density storage systems?

High-density pallet rack creates tall, compact storage structures over a relatively small footprint, taking advantage of vertical space while reducing dedicated aisle space. There are a variety of high-density systems, but two of the more popular types are push-back rack and double-deep pallet rack.

Double-deep rack, not surprisingly, is a two-deep pallet storage system that effectively just deepens a standard selective rack. Nothing fancy, just four pallets per bay — two pallets across and two deep.

Push-back rack can also store two across and two deep per bay, though it can extend to 3 and 4 pallets deep or greater for added capacity. Push-back gets its name from the loading process that places pallets on wheeled carts in the pallet bay – subsequent pallets are loaded by pushing back the pallet already in the lane. Extracting pallets from the lane prompts the rear pallets to flow forward via the wheeled carts.

Raised I beam Base cropped - Apex Companies

Double-Deep Pallet Bay

Push-Back Pallet Bay

Although push-back has moving parts, it’s not a difficult system to access for forklift operators and isn’t much more complicated to maintain than double-deep. However, it may surprise you that double-deep is a bit more challenging to load and extract pallets and requires specialty forklift equipment. We’ll dig into that further below.

So, how do you quantify the similarities and differences between these two systems to find the one that works for you?

A Closer Look at Operational Parameters

To weigh your pallet racking options, your estimate should include the system cost plus the labor and equipment needed to access the rack. Try using these data points to help you choose the system that will meet your ROI goals.

Initial rack cost
Annual labor expense
Cost per sq. ft. of space per year
Useful equipment lifespan

Let’s put this process into action.

Initial Cost

A push-back system typically costs up to 40% more vs. a comparable double-deep system – a substantial cost difference up front.

Material Handling Equipment

Push-back allows you to use standard sit-down forklifts.
Double-deep requires specialty forklifts, experienced operators, and safety features such as cameras to help the driver clearly see the rear pallet position.
Deep-reach trucks are typically more expensive to buy and have higher maintenance costs.

Labor

Loading and picking pallets in double deep takes more time, particularly at higher elevations, vs. push-back, where pallets sit at the pick face.

Equipment Lifespan

Double-deep systems typically incur more damage due to how the forklift access the system. Using an I-beam or sloped leg design will help minimize rack damage. Column guards help protect the system, as well.

From an initial cost standpoint, it may have seemed that double-deep had the competition locked… a 40% higher system cost? But, further examination shows that a higher system price doesn’t necessarily relate to a higher overall cost when you figure in related labor and equipment.

Deep Reach Single Row Pallet Rack - Apex Companies

Double-Deep Rack with Sloped Leg

2-Deep Push Back Pallet Rack- Apex Companies

Push-Back Rack

Pallet Rack Comparison By the Numbers

Now that we have an idea of the system’s operational differences let’s add some numbers for a quantifiable comparison.

Assumptions:

Goal – 10,000 pallet moves a day
10-hour workday
$75,000 for a forklift, battery & charger – annual
$125,000 operator labor & benefits costs -annual

Deep-reach trucks can complete 11 moves per hour as it takes longer to put and retrieve pallets from the back (second) pallet position.

Standard single-reach forklift used in push-back can complete 18 moves an hour – rear pallets flow to the forward pick position for easier, faster access.

Deep reach – 10,000 / 120 ( 11 moves x 10 hours) = 84 forklifts needed with operators

Single reach – 10,000 / 180 ( 18 moves x 10 hours) = 56 forklifts needed with operators

ROI Comparison:

The initial excess investment in the push-back rack is returned in just a few months. The labor and equipment savings for 28 additional forklifts and operators far exceed the material and installation variance between the rack systems.

84 – 56 forklifts = 28 more deep-reach forklifts needed to access the less costly system to get the same 10,000 pallets per day target.

28 forklifts x $200,000 ( $75,000 + $125,000) = $5,600,000 savings per year and a 5-year extended savings of 5 x 5,600,00.00 = $28,000,000.

Going From Concept to Pallet Rack System Selection

Push-Back Rack with Guard - Apex Companies

Conceptually, this comparison may show the benefit of one system vs. the other. Still, every system design is based on unique inventory specs, facility size, turn rates, labor, equipment… you get the idea. What we can tell you is that working with an experienced systems design team will get you all the facts and figures you need to make the right choice for your operation.

Call the Apex team for full-service support from concept to installation and beyond.

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