As your business grows, you need to scale up your operations. In some areas this is a simple process, like upgrading to the next software subscription tier. In other areas, however, growth can bring significant challenges.
Take warehouse storage. There are two ways to increase the size of your premises: expand your current site, or move to a different one. Both are expensive and time-consuming, and have the potential to interrupt the momentum that you’ve worked so hard to build.
But there is a third, more appetising way to ensure your warehouse keeps up with the success of your business: making the most of what you’ve already got.
High-density racking systems and vertical racking systems are designed to do just that: maximise warehouse space, so you don’t need to renovate, relocate or slow your growth.
In this guide we’ll take a look at vertical and high-density racking systems in NZ: what they are, why they’re popular options, and how they can be utilised for warehouse storage optimisation.
What is high-density racking?
High-density racking systems do precisely what they say on the box: store more inventory in a given space. Different varieties of high-density racking approach this challenge in different ways:
- Double deep racking: Similar to selective pallet racking, but pallets can be stored two deep. Placing two racks back-to-back increases the capacity of the rack to four deep.
- Drive-in/drive-through racking: Pallets are placed on moveable rails to reduce the number of aisles in the warehouse, and forklifts can drive directly into or through the rack structure to load or retrieve inventory. Best for last-in, first-out (LIFO) systems.
- Push-back racking: A gravity-based feed sees a forklift push back any pallets already in the slot to make room for a new one. The other pallets in the rack move forward automatically whenever a pallet is unloaded.
- Narrow aisle racking: Narrower aisles can increase available storage space by up to 40%. With aisle widths as small as 1.5m, this racking demands specialist forklift trucks with rotating forks.
- Mobile racking: Mobile shelving systems feature shelving units mounted on tracks, enabling them to slide or move. Popular for archiving and long-term storage, these units can be compacted when not in use and expanded whenever access is required.
All of these high-density storage options have the same aim: to fit more inventory in a given space. The right option for you will depend on the items you store, the warehouse machinery you use, the limitations of your space, and your preferred inventory system (e.g. LIFO or FIFO).
Why maximising vertical space makes business sense
Warehouse design optimisation isn’t limited to high-density storage options. Your warehouse could already have plenty of unutilised space – you just have to look up.
By building your racking higher, and capitalising on all that space in the top half of your warehouse, you can increase your storage capacity without increasing the footprint of your racking at all.
Building vertically also means your storage system delivers better ROI. The extra costs are minimal, as it may not be new rows of racking, it could be simply adding more on top. Vertical racking also represents a warehouse efficiency solution. It can allow you to maintain a selective racking system, avoiding the need to move to double-deep or push-back systems, which can enhance stock visibility and picking efficiency.
Best practices for implementing high-density racking systems
How do you go about implementing a space-saving warehouse racking system? Best practices include:
- Assessing your warehouse layout and ceiling height to understand whether high-density or vertical racking represents the wisest choice for your business.
- Choosing the right racking type for your inventory and warehouse systems: LIFO/FIFO, shelving vs pallet racking vs cantilever racking.
- Ensuring racking is designed and installed according to NZ safety standards.
- Allowing for safe equipment access, such as using VNA/reach trucks for narrow aisle racking.
- Training staff on loading/unloading procedures for high-density and particularly tall racking systems.
- Conducting regular inspections and maintenance to ensure ongoing structural integrity.
Safety considerations for vertical storage
The bigger they are, the harder they fall. If you choose to build your racking up, you need to ensure it is structurally sound. On top of aligning with WorkSafe safety standards, you should:
- Make load capacities clear through SWL signage.
- Consider installing anti-collapse mesh or backstops.
- Ensure your racking is rated for seismic activity according to local risks.
- Conduct regular in-house inspections and annual expert inspections.
- Use barriers and bollards to protect workers and structures.
- Provide staff training on height safety protocols.
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.
When to invest in high-density racking systems
You should be forward-thinking with your warehouse layout planning. Whether you’re managing pallet racking for small warehouses, or controlling complex inventory systems across multiple sites, you need to be proactive in identifying and meeting your needs before any issues become acute.
Some signs that it might be time to invest in a high-density racking system include:
- You’re running out of both floor space and vertical room in your warehouse.
- You need to store more SKUs, but relocating to a new site isn’t feasible.
- You are looking to redesign your warehouse, and potentially integrate automation.
- You’re preparing for peak season or for projected business growth.
Storepro: make the most of your warehouse
Growth doesn’t necessarily mean you need to go bigger – you may be able to just work smarter. Vertical and high-density racking systems help your business do what all good businesses should: optimise, become more efficient, and make the most of what they’ve got.
But optimising your storage system can be a complicated business, particularly if you haven’t done it before. With a wealth of different systems and solutions available, this is a job that benefits from some professional guidance.
At Storepro we are that professional. Our expert team is ready to offer all the high density and vertical racking guidance you need to enhance the storage capacity and performance of your facility.Get in touch with our friendly team today for a free consultation, and take the first step towards smarter, safer and more space-efficient storage.