Drive in Pallet Racking for Cold Storage

Drive-in pallet racking, also known as drive-in and drive-through racking, is a high-density pallet racking system consisting of multiple racks that form internal aisles with support rails to accommodate pallets. Forklifts enter the structure and move within these aisles to load and unload goods. Due to the height and depth of the aisles, this solution makes full use of the available space and increases storage capacity compared to traditional pallet racking.

Advantages and Disadvantages of drive-in & drive-through pallet racking

The drive-in/drive-through pallet racking system is a compact storage solution that meets a variety of requirements. Its storage capacity is greater than that of traditional racking. In addition, it is the simplest and most affordable system compared to other high-density storage solutions. However, since the forklift must enter the rack, storage and removal operations require more maneuvering time. In addition, since each storage aisle is reserved for only one SKU, drive-in pallet racking is not recommended in warehouses that manage a wide range of products. For these situations, Spieth racking has other compact solutions that help manage a more diverse range of merchandise. These solutions include active live pallet racking, push-back racking, and pallet radio shuttle racking systems.

Dimensions of drive-in pallet racking

What is the maximum height of a drive-in pallet rack?

There are no structural limitations to the design of drive-in racking systems. However, the maximum height of these racking units will depend on the maximum lifting capacity of the handling equipment used and the maneuvering assistance systems they contain (cameras, height preselectors, etc.).

How high is each storage level?

The height of each drive-in pallet rack storage level depends on the height of the pallet and the type of construction system used to build the rack (with GP tracks or with C tracks). In the first case, the height of the storage level is equal to the height of the pallet plus 150 mm. For systems with C tracks, the height of the storage level is equal to the height of the pallet plus 200 mm.

How deep is each storage lane?

The depth of each lane is the sum of the depth of all pallets (including load dimensions if goods protrude) plus a minimum clearance of 25 mm per unit load. At the same time, the number of pallets stored in each lane is usually a multiple of the pallets that a production batch or truck can accommodate. For example, a lane for a drive-in unit storing completed orders can be designed to accommodate 11 pallets deep and 3 pallets high. This will increase the pallet capacity of the trailer to 33.

Use of drive-in pallet racking system

How are goods distributed in drive-in pallet racking?

For maximum efficiency, all pallets stored in the same storage aisle should have the same SKU. This avoids unnecessary handling.

Which side are pallets handled in a drive-in pallet racking system?

Unlike conventional pallet racking, compact drive-in racking handles pallets from the wider side, with the pallet bottom deck perpendicular to the support profile. That is, the forklift stores the pallet by positioning its bottom deck at a 90° angle to the support rails.

Which forklift is suitable for drive-in pallet racking?

Drive-in pallet racking uses counterbalanced and reach trucks. While counterbalanced forklifts are usually no taller than 7.5 meters, reach trucks can reach heights of more than 11 meters.

Given that the forklifts travel within the storage aisles, sufficient clearance must be calculated to allow them to work safely (e.g. a minimum clearance of 75 mm between the sides of the forklift and the vertical elements). Likewise, the first layer of support rails must be at a height that does not interfere with forklift components such as the chassis.

Difference between drive-in and drive-through pallet racking

Depending on the type of load management strategy required, this high-density storage system can be configured in two ways: drive-in or drive-through racking. In the first and most common one, loading and unloading operations are carried out from the same working aisle. Therefore, inventory management follows the LIFO (last in, first out) principle. In drive-through storage, on the other hand, pallets are stored and retrieved in two different aisles: goods enter from one end and are taken out from the other. In this case, the loading/unloading sequence is carried out according to the FIFO method (first in, first out). This configuration is often adopted when the system is used as a buffer or temporary warehouse to effectively regulate the flow between two working areas (for example, between production and dispatch or between different manufacturing stages).