Introducing the New Apex Pallet Rack System Comparison Matrix

Find Your Ideal Pallet Rack System with Our New Comparison Matrix 

 

Selecting the right pallet rack system for your business can be daunting for several reasons. First, it is a significant capital expenditure that’s meant to last a long time, and secondly, there are a lot of variables in system design and function. 

To set you on the right track to finding the best storage solution for your unique needs, the Apex team created this Pallet Rack Comparison Matrix. The guide compares the most popular pallet storage systems one to another and against bulk storage to simplify the selection process. 

While pallet rack and storage applications vary considerably e.g., from fast-paced e-comm fulfillment centers to large freezer warehouses for national food processors — the operational goals remain the same. Namely, optimizing warehouse space while processing orders most efficiently. The Apex Pallet Rack Comparison Matrix is general enough to cover a wide swath of industry applications while specific enough to help you find the storage medium specific to your needs.  

How to Use the Apex Rack System Comparison Matrix

 

Step one is knowing your operational parameters –including inventory mix, throughput, warehouse space, equipment, and team capabilities. Next, refer to our Comparison Matrix to narrow down the choices using six key categories, i.e. pallet density, selectivity, productivity, cost, operator training, and type of equipment needed.

Simply choose the parameters most significant to you and analyze the systems that score best in those categories. If you need a system refresher for the storage rack options, see the brief descriptions below. The Apex team can also help configure and install your pallet rack system when you’ve made your selection. 

 

Pallet Storage Systems Comparison 

 

System #1 – Bulk Storage

 

Bulk storage refers to large quantities of inventory often contained in original containers and without packaging. Inventory can include liquid products such as petroleum, industrial supplies such as construction materials, and raw materials for food processing. Bulk storage relies less on storage rack and allows fast 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 among the most convenient type of pallet racking offering portability, customization, and space-saving vertical storage. Stack rack is fast to install and reconfigure as inventory mix changes.

 

System #3 – Selective Rack

 

 

Selective pallet rack – provides reliable, cost-effective pallet storage for low-volume, high-SKU inventory. Pallets are stored in single-deep rows for 100% SKU selectivity and supporting FIFO inventory rotation. Maximize floor space by positioning rack rows back-to-back.

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 stores two pallets deep in the bay vs. single-deep in a selective rack. A major advantage of this design is that it provides twice the pallet volume with 50% less aisle space. Similar to selective, deep-reach is often configured back-to-back to maximize floor space. Deep-reach is sometimes called double-deep rack. 

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 provides high-density storage for high volumes of the same or limited SKUs. It is a LIFO storage system with single-aisle access, allowing for a deep, compact design. The unique storage lanes are equipped with horizontal rails that run the full depth of the system which can go up to 10+ pallets deep.

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 density of drive-in rack while also providing single lane selectivity. Wheeled carts sit stacked at the pick aisle of each lane. A pallet is placed on the top cart, then to load the next pallet, the forklift gently pushes it back, exposing a cart underneath. The process continues until all carts are used, with the last pallet resting on the rails. As pallets are extracted, the rear pallets automatically flow forward, producing a highly effective 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 a high-density, FIFO storage system best suited for an inventory mix with a limited number of high-volume SKUs. The system design is tightly configured, packing in a high number of pallets in a condensed space. Flow lanes have wheeled or roller rails installed on a slight pitch to automatically flow pallets from the load side to the pick aisle.

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 optimize warehouse capacity vs. traditional static rack by eliminating forklift aisles between rack rows to produce a highly condensed footprint for more pallet storage in less space. Automated shuttles reduce reliance on forklift operators, equipment, and travel time to store and access pallets in 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 is a high-density, deep-lane pallet storage system using automated, low-profile shuttles to index pallets within the racking. Cranes or forklifts load the pallets into the racking then shuttles secure the pallet to transport it to designated storage bays. The process is reversed for extraction.

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

 

The Comparison Matrix is a useful tool to help you narrow in on the type of system that can meet your needs; however if you need system design support, engineering, installation, and project management for your project, you only need to call one team. The Apex team offers full-service support for you from the earliest planning stage through to professional installation and final sign-offs. Our team is with you each step of the way to ensure that your project is seamless and expertly executed. 

Call Apex today to speak with our warehouse design experts.