Sizing Up Pallet Racking for Automation Integration

Building Flexibility Into Your Modern Warehouse Design with Pallet Racking

Yes, you read that correctly – and no, steel pallet rack frames are not physically flexible; however, your pallet racking may be more accommodating to meet today’s warehousing demands than you realize. If your existing facility is transitioning from bulk orders to smaller, more individualized orders, pallet rack may be just the support you need. Likewise, if you’re in the planning phase of a new warehouse that will rely on automation, pallet racking may still play a role in upstream and downstream activities.

With the range of storage rack configurations available, you can maximize your warehouse space and minimize touches and processing costs. Here is an overview of the possibilities that pallet racking can provide in a modern warehouse setting.

Pallet Racking Advantages in Modern Warehouse

• Optimizes space use
• Integrates with automation solutions
• Adapts to inventory fluctuations
• Increases throughput
• Enhances warehouse safety 

Optimizes space use: Pallet racking allows for efficient utilization of vertical space, maximizing the warehouse’s storage capacity. Gone are the days of 25’ ceilings and a maximum of 3 or 4 levels of pallet storage rack. Today’s facilities have soaring vertical space that high-density rack systems can optimize, freeing up floor space for other activities and safer maneuverability. Automated equipment works seamlessly with these racks to access and store pallets. Moreover, integrating conveyors within the racking can facilitate the most efficient, safest route while also freeing up available space. 

Integrates with Automation Solutions: As noted above, powered conveyors can work alongside storage racking for popular activities such as kitting and order picking. ASRS systems often use conveyors to process pallets and mini loads for storage and retrieval from the racking. In general, integrating your racking system with powered conveyor facilitates fewer touches,  faster processing, and more accurate inventory management. 

Additionally, pairing your racking system with automated equipment such as pallet shuttles, robotic picking arms, mobile robots (AMRs), automated guided vehicles (AGVs), and other material handling technology improves speed and efficiency and reduces reliance on costly manual labor. For example, pallet shuttles autonomously ferry pallets into and out of deep-lane, high-density storage racking, while VNA (very narrow aisle) turret trucks raise workers up to hand pick items from tall racking while expertly maneuvering within narrow aisle configurations.

Adapts to Inventory Fluctuations: Pallet racking is inherently modular, allowing for reconfiguration and expansion as the warehouse’s needs change over time. This adaptability is particularly beneficial when working with automated systems that might require adjustments based on evolving operational requirements. Your storage racking also supports your inventory rotation, whether First-In-First-Out (FIFO) or Last-In-First-Out (LIFO), to help improve efficiencies. Pallet flow rack is a high-density system typically configured for FIFO but can accommodate LIFO, and drive-in storage systems are typically LIFO but can be reconfigured for FIFO if inventory needs warrant. 

Increases Throughput: The combination of pallet racking and automated systems can significantly enhance the throughput of the warehouse. With right-sized storage racking, you can go from full pallets to case picking to each item selection. Powered conveyors transport inventory at any stage to quickly and accurately streamline the order fulfillment process.

Enhances Warehouse Safety: Pallet racking systems are designed with safety in mind, ensuring that pallets are stored securely and without the risk of collapse. When combined with automated systems, the risk of accidents caused by human error, such as forklift collisions, can be significantly reduced.

Flexible Pallet Racking & Carton Storage to Enhance Automation Productivity

How Does Selective Rack Support Automation?

Selective pallet racking is the most common storage racking system due to its simplicity and affordability. The simple, modular design is perfect for scalability. With wire decking on the lower levels, selective transitions from full pallet storage to full pallet in the top levels and case and each item storage below. Selective is typically a single pallet deep but can also be designed for two-deep (called Deep-Reach). Back-to-back positioning of the rack rows maximizes warehouse space by reducing the number of aisles needed, and configuring the rack in a narrow or very narrow design further reduces the footprint. However, very narrow aisle configurations require specialty forklift equipment.

Options for Pairing Selective Rack & Automation Solutions

• Selective rack is an ideal storage solution for narrow and very narrow aisle designs accessed with AGVs (pallet stackers, counterbalanced forklifts, reach trucks, and very narrow aisle trucks).
• Selective racking can also be used to support your conveyor lines… physically by running the conveyor within the racking structure to optimize space and efficiency.

Selective Rack Advantages

• Ideal for low-volume, high-SKU inventory
• Supports FIFO inventory rotation
• Easy to use, accessible to standard forklifts
• Accommodates a range of pallet dimensions
• Compatible with automated material handling equipment

How Does Gravity Flow Rack Support Automation?

Pallet flow rack stands out for its exceptional pallet storage density in a compact footprint. Pallet flow is a FIFO inventory rotation solution ideal for inventory with limited high-volume SKUs. Individual SKU storage lanes incorporate wheeled or roller rails set at a slight incline. The flow rails facilitate pallet movement from the loading side to the picking aisle. Rear pallets automatically advance as forward pallets are removed from the lane. This design minimizes travel time, subsequently reducing labor and equipment expenses.

Options for Pairing Pallet Flow Rack & Automation Solutions

• Pallet flow rack is a mainstay of case picking applications –whether mezzanine level as seen above or as part of a multi-level pick module or pick tunnel. 
• Pallet flow is compatible with AGVs for pallet loading and unloading.

Pallet Flow Rack Advantages

• Scalable for up to 10+ pallets deep
• Ideal for a moderate number of high-volume SKUs
• Consolidated footprint minimizes travel
• FIFO inventory rotation – ideal for dated goods
• Easily interfaces with automated equipment & picking technology

Aside from full pallet storage, pallet flow racking is also an excellent solution for ergonomic case picking. Additionally, lower pallet flow levels can be configured for high-density case and single-item storage using carton flow rack. Carton flow is the gravity flow solution for high-volume, medium-turn cases, totes, and eaches. There is a wide range of carton flow products to match all your inventory size and weight needs.

Options for Pairing Carton Flow Rack & Automation Solutions

• Carton flow pairs with order-picking technology such as pick-to-light and voice picking for quick, accurate item selection.
• Carton flow is also often used within pick modules for case or each pick to powered conveyor.
• Carton flow is also compatible with robotic picking from AMRs and robotic picking devices.

Carton Flow Advantages

• Creates orderly SKU lanes –facilitates quick, accurate picks
• Consolidates case, tote & each storage – up to 40 SKU lanes per bay
• Supports FIFO rotation
• Ideal for high-volume, medium-turn inventory
• Enhances order pick technology function

Automated Storage and Retrieval Racking

Automated storage and retrieval systems (ASRS) blend storage racking and automation to optimize space AND processing functions to levels that can transform your warehousing operation. ASRS incorporates intelligent automation to streamline pallet, unit load, mini load, and single item storage and retrieval, eliminating human errors and reducing time spent locating and transporting goods. The increased accuracy and speed translate into higher throughput with greater accuracy and speed. 

ASRS is a scalable solution that seamlessly integrates with warehouse management software, enabling real-time tracking, inventory management, and data-driven decision-making. In the ever-evolving landscape of modern warehousing, automated storage and retrieval systems stand as a cornerstone for elevating operational effectiveness and meeting the demands of a dynamic market.

ASRS Advantages

• Consolidated, high-density storage
• FIFO or LIFO storage
• Ideal for high-volume, high-throughput inventory
• Scalable for full pallet or mini-load, and fully- or semi-automated
• Real-time inventory tracking
• Enhanced throughput with near-perfect accuracy

Options for Automated Pallet Storage & Retrieval

There are two primary mechanisms for automating pallet storage and retrieval –pallet shuttle systems and stacker cranes. Conveyor systems and/or robotic forklifts can be paired with ASRS solutions to feed and take-a-way pallets from the system.

• Pallet shuttle ASRS uses free-standing pallet racking and autonomous runners (semi- or fully automated) to facilitate the placement and extraction of pallets. The shuttles are directed by a customized software control system fully integrated into the WMS.

Inventory control software optimizes placement of the pallets to maximize space and throughput. The shuttles move at high speeds and deliver near-perfect accuracy and high-throughput results. 

Pallet shuttle systems are also scalable, allowing room for growth to support future inventory expectations. 

• Unit load ASRS systems are a fully automated solution used for high-density inventory storage of pallets or containers — Your system is configured to your inventory specs to ensure maximized capacity and productivity. These free-standing rack configurations use AGVs or conveyors to feed inventory into and away from the racking structure while stacker cranes operate within the racking to efficiently store and retrieve items. Typically tall structures, unit load ASRS is ideal for maximizing vertical cube space.
• Rack-supported buildings for ASRS systems take inventory storage and access to a whole new level. Rack-supported buildings use steel racking for the frame of the structure and for the rows of pallet storage within it. Cranes or shuttles ferry the pallets in and out of the storage locations, while conveyors provide pallet entry and egress from the storage racking. These facilities are highly efficient, relying almost entirely on automated systems to operate. Check out a recent installation…

Rack-Supported Building Installation

Building the Frame & Interior Rack

Loading Stacker Crane Between Rack Rows

Automated Storage & Retrieval for Totes & Single Item Inventory

Technology is adaptable, and it’s being put to good use with new and evolving ways to store not only large, heavy pallet loads but small individual items… and everything in between. Some of these applications use custom structures, but others use modified storage racks, again demonstrating that where your needs lie, there’s a solution tailor-made to handle it.

Mini-Loads

Using cranes, robotic arms, or self-guided vehicles, mini-load systems access items stored in highly-compact aisles. It accommodates various container types, including cartons, bins, totes, and trays, and can be tailored for specific uses like pharmaceuticals or perishables. In addition, these systems offer exceptional reliability and demand minimal maintenance, providing an extra benefit.

ASRS Carousels

Horizontal and vertical carousels employ an array of shelves or trays enclosed within an automated storage unit –oriented either horizontally or vertically. These systems offer rapid item retrieval, as the carousel can be instructed with minimal commands to fetch any item within its inventory.

AMR Systems

Autonomous mobile robots (AMRs) have evolved order picking into a goods-to-person solution that meets one of the most significant warehouse challenges. Utilizing digital mapping and advanced sensors, AMRs safely traverse your facility, skillfully avoiding both people and obstacles on their way to specified cube storage units. The robots slide beneath the storage units, elevate them, and transport them to fixed pick-and-pack stations. After completing their task, they efficiently return the storage unit and proceed to their next assignment.

Vertical Lift Modules

Vertical lift modules are fully automated storage solutions that optimize vertical space, reaching heights of 50 feet or more while offering rapid goods-to-person item storage and retrieval. They excel in organizing small items, such as medical supplies and electronic components, and can be effortlessly activated through barcode scanning or touchpad operation. With permission-based access controls and comprehensive reporting features, VLMs enhance inventory management and tracking capabilities. Surprisingly, VLMs accommodate load capacities ranging from a few hundred to several thousand pounds.

Pallet Racking

Integrating Great Ideas Into Effective Solutions

As is clearly evident, a range of options can be applied to each application of your warehousing operation. Pallet racking, combined with automation solutions from conveyors and pallet shuttles to order processing tools, offers a range of benefits that contribute to a more efficient, productive, and cost-effective modern warehouse configuration. If you’re interested in exploring the best way to optimize your space to most effectively meet demand, call the Apex team for a free consultation. Apex provides full-service support from design and engineering through permitting and project management, and installation. Your relationship with Apex also continues after final signoffs –the Apex PROs are the team to call for your warehouse rack and safety inspections, maintenance, and repairs. 

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