Third party logistics (3PL) warehouses face a challenge.
Warehouse storage optimisation is critical: you need to maximise capacity through clever utilisation of your available space, in order to cope with varying levels of client inventory, and to ensure you aren’t paying for extra room that you may not necessarily need.
But you also need to ensure that you have easy access to inventory, so items flow through your facility efficiently.
Maximising storage and maximising efficiency are often thought of as yin and yang in 3PL warehousing: dialling up one can dial down the other. But that doesn’t necessarily have to be the case.
In this guide we’ll take a look at double deep racking: a storage solution designed to maximise storage capacity, but that, when used strategically, can deliver high-density 3PL storage without affecting warehouse access efficiency.
What is double deep racking and how does it work?
Double deep racking is similar to standard selective pallet racking, with one key difference: you can store pallets two deep, which doubles the capacity of your rack. And when you place two racks back-to-back, you increase the capacity of the rack to four pallets deep.
Comparing selective racking vs double deep, selective systems ensure all pallets are always accessible, but are more space-hungry. Double deep racking, meanwhile, increases storage capacity but can reduce accessibility.
Double deep warehouse racking systems work on a last in, first out (LIFO) basis, i.e. the last pallet to be placed on the rack is the first to be taken off again. LIFO is an ideal solution for 3PL providers that don’t work with perishable stock, and don’t require so much client inventory rotation. Deep reach forklifts are required to access the second pallet.
In terms of warehouse layout optimisation, the typical split for double deep racking is 55% storage and 45% working area.
Benefits of double deep racking in 3PL warehousing
Space utilisation is where double deep racking systems shine. They can boost the storage capacity of your warehouse by up to 50%, which can allow a 3PL provider to lease a smaller space and/or avoid the expensive process of moving operations to a larger facility.
This drives two major flow-on benefits:
- Improved floor space utilisation: More usable room for inventory receipt, transport, picking, packing and dispatch.
- Lower cost per pallet stored: Save money by leasing a smaller space or maximising your use of the space you have.
Double deep racking is ideal for 3PL providers who deal in medium-turnover SKUs or batch/bulk storage.
Common misconceptions and trade-offs
While it’s true that double deep racking does trade storage capacity for accessibility, it doesn’t necessarily reduce access across the board.
If you store multiple pallets of the same product, and that product isn’t perishable, double deep racking can see you increase your storage capacity significantly with no real ill effects on accessibility.
The system is also still viable with smart slotting and product rotation strategies, but the more selectivity you require, the less compelling the extra storage capacity becomes.
It’s up to each 3PL warehouse to decide which factor is most important to them. Many will use a combination of double deep and selective racking to capitalise on the benefits of both.
When to use double deep racking in a 3PL setting
So, is double deep racking good for 3PL? It certainly can be, particularly in the following scenarios:
- 3PL providers who deal in bulk goods and low SKU variety
- When clients have multiple pallets per SKU
- Warehouses with high throughput and consistent stock flow
- Facilities handling batch picking or zone-based fulfilment
Comparing double deep racking with other systems
How does double deep compare with other types of pallet racking for logistics? Here’s a summary of how the most popular 3PL racking systems compare:
Racking Type | Storage Density | Selectivity | Accessibility | Upfront Cost | Best Use Case |
Low | High | Excellent | Low | High SKU variety, fast picking, low volume per SKU | |
High | Moderate | Good (requires deep reach forklift) | Low to Moderate | Medium SKU variety, moderate turnover | |
Very High | Very Low | Limited | Moderate | High volume, low SKU count, low turnover | |
High | Moderate | Good | High | Moderate SKU variety, maximum space utilisation |
Design and equipment considerations for implementation
When designing your double deep racking, there are a few key factors you should consider in terms of layout, accessibility and equipment:
- Deep reach/pantograph forklifts: You’ll need to invest in forklifts that are capable of reaching the rear pallet.
- Aisle width: You need to ensure that your racking is spaced far enough apart to allow your chosen forklift to comfortably turn around within it.
- Racking reinforcements: Heavy pallets may necessitate reinforced racking to ensure the safety and stability of your storage system.
- Traffic flow: Carefully consider how traffic will flow through your warehouse, and design a layout that maximises efficiency.
Safety and compliance in NZ
Every aspect of your double deep racking system must align with WorkSafe safety standards. The specifics will depend on your situation, but basic principles include:
- Ensuring racking does not block emergency exits or fire systems.
- Labelling racking with SWL signage and other key information.
- Inspecting racking according to WorkSafe guidelines.
- Using barriers and bollards to protect workers and structures.
- Keeping heavy items at lower levels where possible.
A quality racking supplier like Storepro will be happy to guide you on all the regulatory boxes you need to tick in order to comply with NZ warehouse safety rules.
Storepro: double deep racking professionals
Double deep racking isn’t the right storage system for every 3PL provider. But when deployed correctly, it does offer an ideal middle ground for any 3PL facility juggling storage capacity and inventory access considerations.
Is double deep racking the right choice for you? Answering that question correctly can require some professional storage expertise.
At Storepro we are that professional. Our expert team is ready to offer all the 3PL warehouse racking guidance you might need, while enhancing the performance of your facility through a custom designed, high quality storage solution.
Get in touch with our friendly team today for a free consultation, and take the first step towards smarter, safer, more efficient 3PL warehouse racking.