Pushback Pallet Rack System

A pushback rack system uses multiple, nesting pushback carts to create a high density LIFO storage solution.

What Is Pushback Pallet Rack System?

Pushback racking is a high-density storage system used in warehouse and distribution centers to maximize space and efficiency. This system utilizes a series of inclined rails and carts to allow for deep storage of multiple pallets. As each new pallet is added, it pushes the previous pallet back along the rail, hence the name “pushback” racking.

This innovative design enables organizations to store a greater number of pallets in a smaller footprint, making it an ideal solution for high-density storage needs. The pushback racking system also facilitates the first-in, last-out (FILO) inventory management method, ensuring efficient rotation of stock and minimizing the risk of product spoilage.

While pushback racking offers numerous benefits, including increased storage capacity and better drive-in accessibility to stored items, it is important for to carefully consider their specific storage needs and operational requirements before implementing this system. Proper installation and maintenance are essential to ensure the safety and stability of pushback racking, making it crucial for warehouses to increase the storage density.

Pushback rack systems can typically support 2 to 5 pallets per lane when front pallet is removed.

How Push-back Pallet Racking Systems Work

A pallet is loaded on a cart at the front of the bay. To load a subsequent pallet, the loaded forklift pushes the first pallet back (which rolls easily because of the cart it is resting on), and places the second pallet on the next cart in the nested stack moving last pallet towards the back.

This process is repeated multiple times for as many carts as the system holds. Because the drive-in rack and pallets are stored at a slight incline push-back system for pallets, nest pallet automatically rolls to the front of the bay when pallets are removed making load and unload very easy.

Push back Racking System Benefits

The advantage of warehouse pushback racks is that they allow more pallets to be stored by eliminating the number of aisles necessary to pick and put away materials. A single aisle may allow access to pushback system holding up to six pallets on each side of the aisle. The extra space that would normally be used for aisles can be used for additional storage.

High density means less wasted aisle space
Pallets roll to the front of the lane for easy retrieval
Increased storage capacity within the same footprint
Greater accessibility to individual pallets
Improved inventory management and organization
Reduced labor and equipment costs for storage and retrieval
Enhanced safety measures for workers and products
Potential for better utilization of warehouse space and resources.

Limitations of Pushback Racking Storage System

Maximum depth of 5 bays per lane.
LIFO system does not work well for perishable products
Limited accessibility to individual pallets within the system
Limited flexibility for managing changes in SKU mix and inventory levels
Requires specialized forklifts or other handling equipment
Higher initial investment compared to standard selective racking systems
Not suitable for large or heavy pallets
May not be suitable for all warehouse layouts and configurations
Potential for damage to stored goods if not operated properly
May require regular maintenance to ensure proper functioning

When to Use Push Back Racking Pallet System?

There are several factors when evaluating when pushback rack makes sense for your project. If all of the below items are true, pushback warehouse racking could be a good fit.

Adequate budget — pushback rack is more expensive than selective pallet rack
You need high density – you need to store a lot of items in a small space
Products are palletized – you typically store your products on standard size pallets
Products have a long shelf life – perishable products don’t work well in a Last In First Out inventory system
Several pallets of the same SKU – it’s inefficient to put different SKU’s in the same bay, so you should commonly have at least three pallets of the same SKU
Frequent inventory rotation – you have a large amount of inventory that needs to be accessed frequently and in a specific order
Limited SKU variety – you have a limited number of SKU’s that are stored in bulk quantities
High volume throughput – you have a high amount of pallet movements in and out of the racking system
Limited warehouse space – you need to maximize your storage capacity in a limited storage solution.

The roller and shuttle systems offer high compaction and resistance, making them compatible and adaptable with other adjustable pallet rack systems. This makes them an ideal choice for cold storage or freezing environments, especially due to their ability to functionalty of shuttle systems at low temperatures.

Push-Back Type of Racking System Structure

Base metal structure: This is the overall framework of the push-back racking system, providing the foundation and support for the rest of the components. It is typically made of high-quality steel to ensure durability and stability.
Frames: These are vertical uprights that support the beams and other components of the system. They are securely anchored to the floor and may have diagonal bracing for additional stability.
Beams: Horizontal load-bearing members that connect the frames and provide support for the pallets or unit loads. They are designed to withstand the weight and pressure of the stored items.
Crossbeams: These are used to create the surface on which the unit loads are stored. They are attached to the beams and can be adjusted to accommodate various pallet sizes.
Dynamic profiles: These components are used to push the loaded pallet within the racking system. They can be in the form of shuttles or rollers system that allow for easy and efficient storage and retrieval of items.
Safety accessories: Braking and controlling mechanisms are an essential part of the push-back racking systems allow to ensure the safe operation of the unit loads. This may include devices that prevent overloading, as well as features for securing the pallets in place.

Overall, the structure of a push-back type of live storage system allows to provide efficient pallet flow and pallet storage while maximizing space. The roller and shuttle systems work together to generate the live system of pallet racking solution for warehouses (including cold storage) and distribution centers.

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