Pallet Rack Matrix Helps Carolina Businesses Find Their Next Storage System

Choose the Right Pallet Rack Solution for Your Warehouse with Our Matrix

The right pallet racking is a critical component of your efficient warehouse operation. Storage racking represents a significant capital expenditure and allows for optimized use of your space, labor, and equipment. With so much riding on the decision to pick out the right solution, it’s essential to have some expert support. That’s why the Apex Carolinas team is sharing our Pallet Rack Matrix and making it available for download. 

The Apex Pallet Rack Matrix compares the most popular pallet storage options, from bulk stacking and simple pallet racking to complex, high-density, and dynamic systems. It’s a quick reference guide to help get you started in finding the best solution for your warehousing needs.

Although storage and pallet rack applications vary from warehouse to warehouse, the  operation goals are the same: optimized order processing and maximizing warehouse space. The Apex Pallet Rack Comparison Matrix is broad enough to cover an array of industry applications and specific enough to help you find the storage medium for your unique needs. 

How to Use the Apex Pallet Rack Comparison Matrix

Step 1 – Determine your operational parameters. These include warehouse space, inventory mix, equipment, throughput, and team abilities. 

Step 2 – Narrow down your choices using six key parameters: cost, productivity, pallet density, type of equipment needed, selectivity, and operator training. 

For your quick reference, we’ve provided definitions of each of the storage rack systems below. When you’re ready to proceed, the Apex Carolinas team will help you to design and install your custom racking system.  

Comparing Pallet Rack Storage Systems

SYSTEM 1 – BULK STORAGE

Bulk storage is best suited for high-volume inventory stored in containers and unpackaged. Stored in bulk vs. within pallet racking, allows quick and easy access via forklift and pallet jack. Bulk inventory is typically industrial supplies, liquid products, and raw materials.

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 

Conveniently grow your pallet storage rack as needed. Stack rack is a modular design with individual units that stack together. Each unit consists of a base with four welded posts to hold palletized or bulk inventory. The system enables you to create a custom solution to maximize available space. You can also reconfigure as inventory mix, and quantities change.

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)

SYSTEM 3 – SELECTIVE PALLET RACK

 

 

Selective pallet racking provides dependable, cost-effective pallet storage for low-volume SKUs and an inventory mix of a high number of SKUs. Pallets are stored in single deep rows for 100% selectivity supporting FIFO inventory rotation. Selective rack placed back-to-back help maximize warehouse space by eliminating aisles.

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 pallet rack (aka double-deep rack) stores two pallets deep vs. single-deep in a selective system. A major plus is that it doubles your storage capacity in 50% less aisle space. Similar to selective, deep-reach is often configured back-to-back to optimize floor space. Deep-reach systems do require specialty forklift equipment –be sure to check with your Apex representative to help you compare the full system cost benefits.

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 is high-density storage for high volumes of the same or a limited number of SKUs. This LIFO storage system has 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 or more 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 offers the density of drive-in rack with dedicated, dynamic SKU lanes. Wheeled carts sit stacked at the pick aisle of each lane. A pallet is placed on the top cart, then the forklift gently pushes it back, exposing a cart underneath to load subsequent pallets. This process continues until all carts are full. The last pallet rests on the rails. As pallets are extracted, the rear pallets automatically flow forward, resulting in 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 for an inventory mix with a limited number of high-volume SKUs. The design is consolidated, packing in a high number of pallets into a condensed space. The system is loaded and extracted from opposite aisles. The pitched flow lanes lines with wheeled or roller rails automatically flow pallets down 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 systems take consolidated storage to a new level. These systems eliminate forklift aisles between rack rows to produce a highly condensed footprint – more pallet storage in less space. Automated shuttles decrease 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 that uses automated, low-profile shuttles to index pallets within pallet racking. Cranes or forklifts load pallets into racking then shuttles secure pallets and transport them to their 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)

Let Apex Carolinas Help you to Choose the Right Pallet Rack System

We know a lot is riding on your storage racking decision. Apex Carolinas is here to help with our warehouses conveniently located in Hickory and Charlotte, North Carolina, and Greenville, South Carolina. We are your local full-service material handling and storage solutions provider for all things pallet rack, including design, installation, and warehouse safety. Our experts are committed to implementing safe, effective warehouse solutions to enhance the productivity of your operation. 

Call Apex Carolinas today for a free consultation.