EASY TO USE PALLET RACK COMPARISON MATRIX FOR COLORADO BUSINESSES

Apex Pallet Rack Comparison Matrix Uncovers Your Ideal System Design

Choosing the perfect pallet rack system for your business can be quite overwhelming due to various factors. Firstly, it involves a substantial investment intended for long-term use. Secondly, the intricacies of system design and functionality add to the complexity. However, to assist you in finding the ideal storage solution that caters to your specific requirements, the Apex Colorado team has developed a Pallet Rack Comparison Matrix. This comprehensive guide simplifies the selection process by comparing the most popular pallet storage systems with each other and against bulk storage.

Let’s Enter the Matrix…

The initial step involves understanding your operational parameters, encompassing inventory mix, throughput, warehouse space, equipment, and team capabilities. Once you have a clear understanding of these factors, utilize our Comparison Matrix to streamline your options based on six essential categories: pallet density, selectivity, productivity, cost, operator training, and required equipment type. 

Simply prioritize the parameters that hold the most significance for your business and evaluate the systems that excel in those specific categories. If you require a quick overview of the storage rack options, refer to the concise descriptions below. Additionally, the Apex Colorado team can assist you with configuring and installing your chosen pallet rack system.

FIND YOUR PALLET RACK SYSTEM

System #1 – Bulk Storage

Bulk storage typically involves storing vast amounts of inventory in original containers without packaging. The inventory mix can encompass various products, such as liquids like petroleum, industrial supplies like construction materials, and raw materials for food processing. With bulk storage, storage racks play a minimal role, with many facilities opting instead for floor stacking to enable swift access to inventory.

Matrix Specs: Density – 2 Selectivity – 8 Productivity – 6 Cost – $300 Type of equipment – Forklift Operator training – 2

Applications & Advantages: Fast turn rate inventory Minimal expense to set up and maintain Versatile for varying inventory specs Limited vertical cube use Food processing  Industrial

*(Matrix Scale 1-10/10 = Best  | Training – 10 = Hardest)

 

System #2 – Stack Rack

	Matrix Specs: Density – 2 Selectivity – 8 Productivity – 6 Cost – $300 Type of equipment – Forklift Operator training – 2
	Applications & Advantages: Quick and easy to build Flexible design fast reconfiguring Maximize vertical space Cost-effective to custom configure Portable Does not require pallets
*(Matrix Scale 1-10/10 = Best  | Training – 10 = Hardest) Stack racks are a stand-out when you are looking for convenience and flexibility. They provide portability, customization, and efficient vertical storage, that helps optimize your space. Stack racks are known for their quick installation and easy reconfiguration, making them adaptable to changes in your inventory mix.

System #3 – Selective Rack

 

 

When it comes to pallet storage for low-volume, high-SKU inventory, Selective pallet rack solutions offer reliability and cost-effectiveness. With single-deep rows providing 100% SKU selectivity, this rack system supports FIFO inventory rotation. By strategically positioning rack rows back-to-back, you can efficiently maximize your floor space.

Matrix Specs: Density – 3 Selectivity – 10 Productivity – 7 Cost – $150 Type of equipment – Forklift Operator training – 2

Applications & Advantages: 100% selectivity Low-cost storage racking Ideal for low volume, high-SKU inventory Supports FIFO inventory rotation Requires considerable space for aisles Limited pallet density per square foot Versatile for varying inventory specs

*(Matrix Scale 1-10/10 = Best  | Training – 10 = Hardest)

 

System #4 – Double-Deep Rack

 

 

Deep-reach rack offers enhanced pallet storage by accommodating two pallets deep within each bay, in contrast to the single-deep storage of selective racks. This design delivers a significant advantage of doubling the pallet volume while requiring only 50% of the aisle space. Similar to selective racks, deep-reach racks are often configured back-to-back, allowing for optimal utilization of floor space. Another name for deep-reach rack systems is double-deep racks.

Matrix Specs: Density – 4 Selectivity – 7 Productivity – 5 Cost – $150 Type of equipment – Reach Truck Operator training – 4

Applications & Advantages: 50% fewer aisles than selective with twice the pallet volume Low maintenance Requires deep-reach forklift Reduced utilization percentage

*(Matrix Scale 1-10/10 = Best  | Training – 10 = Hardest)

 

System #5 – Drive-In Rack

 

 

Drive-In pallet racking offers a space-efficient solution for high-volume storage of identical or limited SKUs. Operating on a last-in, first-out (LIFO) principle, this storage system features single-aisle access, enabling a deep and compact design. The distinctive storage lanes have full-depth horizontal rails, accommodating up to 10+ pallets deep in the system.

Matrix Specs: Density – 6 Selectivity – 2  Productivity- 2 Cost – $200 Type of equipment – Counterbalance Truck Operator training – 8

Applications & Advantages: High-density pallet storage Ideal for high-volume, low-SKU inventory 10+ pallets deep LIFO stock rotation – drive-in FIFO stock rotation – drive-thru Vulnerable to honeycombing – empty pallet positions due to SKU increase

*(Matrix Scale 1-10/10 = Best  | Training – 10 = Hardest)

 

System #6 – Push-Back Rack

 

 

Push-back pallet racking combines the high-density benefits of drive-in rack with the added advantage of single-lane selectivity. The system consists of wheeled carts stacked at the pick aisle of each lane. To load a pallet, it is placed on the top cart, and the forklift gently pushes it back, revealing a cart underneath. This process continues until all carts are utilized and the last pallet rests on the rails. As pallets are extracted, the rear pallets automatically move forward, facilitating a highly efficient process.

Matrix Specs: Density – 5 Selectivity – 5  Productivity- 7 Cost – $275 Type of equipment – Forklift Operator training – 4

Applications & Advantages: Ideal for high-volume, low-SKU inventory High-density pallet storage system Typically 3- to 4-deep pallet storage Single aisle access LIFO stock rotation Condensed footprint

*(Matrix Scale 1-10/10 = Best  | Training – 10 = Hardest)

 

System #7 – Pallet Flow Rack

 

 

Pallet flow rack is an efficient high-density storage system designed for FIFO inventory management, particularly ideal for limited SKUs with high volumes. This system is tightly configured, maximizing pallet storage in a compact space. Flow lanes are equipped with wheeled or roller rails set on a slight incline, facilitating the automatic flow of pallets from the loading side to the pick aisle. Separate aisle access safely enables concurrent load and pick activities.

Matrix Specs: Density – 7 Selectivity – 5  Productivity- 8 Cost – $375 Type of equipment – Forklift Operator training – 5

Applications & Advantages: High-volume SKU applications High productivity, low labor required Lane depth 2- to 10-pallets deep FIFO rotation ideal for dated goods High cost per pallet position Additional height required per level

*(Matrix Scale 1-10/10 = Best  | Training – 10 = Hardest)

 

System #8 – Pallet Shuttle Rack 

 

Pallet shuttle storage systems revolutionize warehouse capacity compared to conventional static racks by eliminating forklift aisles between rack rows, resulting in a significantly condensed footprint that allows for greater pallet storage in a smaller footprint. The implementation of automated shuttles minimizes the need for forklift operators, equipment, and travel time, streamlining the process of storing and accessing pallets within the system.

Matrix Specs: Density – 8 Selectivity – 4  Productivity- 6 Cost – $350 Type of equipment – Forklift/Shuttle Operator training – 7

Applications & Advantages Gain up to 70% pallet positions vs. static systems Increase throughput with fast, accurate pallet selection Reduce labor and equipment costs Flexible FIFO or LIFO rotation design Protect inventory and rack system from damage

*(Matrix Scale 1-10/10 = Best  | Training – 10 = Hardest)

 

System #9 – ASRS – Automated Storage & Retrieval System

 

ASRS (Automated Storage and Retrieval System) is an advanced, high-density pallet storage solution utilizing automated, low-profile shuttles to efficiently position pallets within the racks. The pallets are initially loaded into the racking by cranes or forklifts, after which the shuttles securely transport them to designated storage bays. The extraction process follows the same sequence in reverse. ASRS offers enhanced efficiency and space utilization.

Matrix Specs: Density – 9 Selectivity – 8  Productivity- 10 Cost – $1000 Type of equipment – Forklift/Crane Operator training – 9

Applications & Advantages High-volume, high-SKU inventory Minimal labor required Cost-effective multi-shift use Commonly used for frozen foods & cold storage

*(Matrix Scale 1-10/10 = Best  | Training – 10 = Hardest)

 

Trusted Pallet Rack & Warehouse Design & Installation

Utilize the Comparison Matrix as a valuable tool to pinpoint the system that aligns with your requirements. However, if you seek assistance with system design, engineering, installation, and project management, look no further than your local Apex Colorado team. We provide comprehensive full-service support, starting from the initial planning phase to the professional installation and final sign-offs. Our dedicated team accompanies you throughout the entire process, ensuring seamless and expert execution of your project.

Call the Apex Colorado team today to speak with our warehouse design experts.