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Push-Back Racking System

Warehouse industrial shelving storage system shelving metal pallet racking

Push-Back Racking System

Push Back Pallet Racking systems are designed to optimize warehouse storage and enhance efficiency. In these systems, pallets are loaded from the front, which pushes the pallets behind them back by one position. When it’s time to unload, the front pallet is removed, and the rear pallets automatically advance to the front picking position. This dynamic ensures a smooth flow of goods and reduces handling time.

Push Back Pallet Racking is famous for its high-density storage capability. Unlike traditional racking systems, which require separate aisles for access, Push Back Pallet Racking consolidates storage into compact lanes. This space-saving approach allows for multiple pallets to be stored in a single lane, significantly maximizing warehouse capacity.

Moreover, Push Back Pallet Racking is ideal for handling various types of products, especially those that are stored in bulk. The system supports first-in, last-out (FILO) inventory management, which is beneficial for products with longer shelf life or those that do not require frequent rotation.

Advantages:

  • High Density Storage- maximizing cubic space – Not Aisles
  • Quick easy access to different size of pallet types
  • Pallet automatically presented at the rack pick face
  • Reduces truck travel distances, and cuts cycle times

Ideal For

  • Used for bulk storage / cold store
  • Different size or types of palletize stocks.
  • Limited Stock Rotation
  • Limited chambers and a single access aisle
Side view schematic of a Push Back Racking System, illustrating multiple storage lanes with carts on rails.

FAQ

Push Back Racking Systems are most effective in warehouses with medium to high-density storage requirements where space optimization is critical. These systems excel in industries that store bulk products, such as food, beverage, chemicals, and pharmaceuticals, where inventory turns are moderate but space efficiency is a priority. The system’s ability to maximize vertical space while maintaining high throughput makes it ideal for facilities with limited floor area.

Push Back Racking operates using a gravity-fed mechanism, where pallets are loaded from the front and pushed back into the racking lanes. It follows the Last-In, First-Out (LIFO) inventory method, making it suitable for products with longer shelf lives or those not requiring frequent rotation.
In contrast, Pallet Flow Racking employs gravity rollers and a sloped system to push pallets forward, ensuring the First-In, First-Out (FIFO) inventory method, ideal for perishable goods or products requiring strict date tracking. Push Back systems offer higher density storage by reducing the need for aisles, while Pallet Flow systems provide faster access for time-sensitive products.

While traditional Push Back Racking systems are optimized for single-SKU lanes to ensure smooth and predictable pallet flow, advanced configurations can support mixed SKUs within the same lane. This requires more precise control mechanisms, such as adjustable rollers or dedicated stops, to prevent pallets from becoming misaligned. This approach allows for more flexible storage while maintaining efficient space utilization, though it may reduce the overall system’s efficiency compared to single-SKU lanes.

Technically, Push Back Racking systems incorporate several safety features to minimize risk:

  • Automatic pallet stop systems to prevent pallets from overhanging or falling during loading/unloading.
  • Brake mechanisms within the rails or carts to control the speed at which pallets move, preventing excessive momentum that could cause accidents.
  • Rack impact protection using heavy-duty bumpers or reinforced posts to protect the racking structure from forklift damage.

Regular safety audits are essential, ensuring proper alignment and load distribution within each lane.

Maintenance for Push Back Racking involves periodic inspection of the following:

  • Carts and rollers: Regular checks for wear or damage to ensure smooth pallet movement. Clogged or damaged rollers can cause jams or slowdowns, leading to operational inefficiencies.
  • Inclined rails: Ensure that the rails are free from debris and properly lubricated to maintain smooth operation.
  • Structural integrity: The racking framework should be checked for structural weaknesses, particularly in high-stress areas like the load-bearing supports.
  • Pallet adjustments: Check that pallet sizes match the racking configuration. Mismatched pallets can cause alignment issues and reduce overall system efficiency.

Scheduled maintenance and cleaning of these components help extend the system’s lifespan and improve operational efficiency.

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