Why Should You Choose Pushback Racking System for Effective Storage Management?

Why Should You Choose Pushback Racking System for Effective Storage Management?

12 Jul, 2024

No matter how large a warehouse is, its’ potential may get restricted when not equipped with effective storage systems. Pushback racking systems are designed to maximize storage capacity and efficiency. Operating on a Last in First Out (LIFO) principle, pushback racking utilizes the vertical warehouse spaces in the best manner.  

They also ensures better handling and increased accessibility. With cost effectiveness, space optimization, and efficient inventory management, pushback racking gives you a competitive edge over other storage methods. 

Let’s explore the advantages, features, and different designs of pushback racking and how it serves as an effective and optimal storage method for modern warehouse needs.

What Is Pushback Racking?

The pushback racking system is an agile and high-density storage solution. This system allows adequate housing of several pallets deep in a single lane, with different stock-keeping units (SKUs) in each lane. 

Pushback pallet racking also has a single loading and unloading pick face at the front, the unit loads are stored by pushing the previous ones to the back of the system. It means each pallet is seamlessly pushed back as new pallets are added; hence the term “push back.” 

Although it’s a LIFO storage system, you can easily switch to First in First Out (FIFO) by storing multiple product lanes. Moreover, the system can be combined with other warehousing storage solutionss, which makes it a more versatile storage option.

What are the Features of Pushback Racking System?

The pushback racking system is thoughtfully designed for LIFO goods management, where the last pallet on the rack is the first to be unloaded. Here are a few more prominent features of pushback inventory management

  1. Easy Movement: This racking system makes use of nested carts and inclined rails for each storage lane. The gravity-assisted movement allows pallets to easily move back and forth within the structure.
  2. Single Work Aisle Accessibility: Unlike the other storage systems, pushback racking does not require a separate aisle for loading and unloading. Here, the forklift does not enter the racking, and the goods can be easily accessed from a single aisle. 
  3. Smart Loading: Forklifts place new pallets into the system by pushing back previously loaded pallets. These pallets are placed on the cart or rail position at the front of the rack, so when new pallets are placed, they push back the previously placed goods to the back of the system.

Effortless Unloading: Similar to loading, unloading also works seamlessly with this system. In order to retrieve a pallet, the operators simply remove the front pallet and the pallets behind roll forward with the help of gravity.

What are Some Special Pushback Designs?

Pushback racking has some advantages to accommodate non-standard applications as it’s customizable. For instance, if your application has plastic pods or you deal with heavy pallets of over 3000 pounds, modified pushback designs will work best for you. 

Some adaptable pushback designs for versatile applications are mentioned below.

1. Ladder Style or Covered Cart Pushback

Not all pallets come in perfectly symmetrical shapes and sizes. Therefore, for weak and odd-shaped pallets or pallets which need more support, 3D Storage System’s ladder style pushback lanes are perfectly suited to handle such non-standard applicatons.

Ladder style lanes provide:

  • Additional Support: For pallets without bottom boards running left/right, ladder style lanes have structural cross ties which help support odd pallet designs. Additional supports can be added – like mesh, bar grating or steel sheets.
  • Fully Supported Rail Positiojn: Ladder systems have cross supports built into the last position, so every pallet position is well supported. 

2. Drive-in Conversion

Due to more product types in their stocks, some customers face trouble with honeycombing in their drive-in systems. To overcome this issue, many warehouses have to reprofile their existing drive-in systems. However, a “drop-in” style pushback system resolves this issue without needing a major overhaul.

Drop-in style pushback lanes are highly preferable for retrofitting existing drive-in rack systems, as they not only save the expense of a new rack but also minimize the installation and labour cost. 

3. Floor Mount Lanes

Floor mount lanes are used to optimize the vertical space in a tight ceiling clearance. These floor mount lanes reduce the starting height of the pushback system by eliminating the beams in the front and internal beam intermediate positions. 

Typically, the first beam height of a standard system is 8”-10”. By utilizing a floor mount, this height is reduced to 3”, this way, it saves 5”-7” of overall height. Not only this, but these floor mount lanes are also helpful while picking cases from the bottom level. 

4. 48” FACE FOR GMA/CHEP STYLE PALLET

This specific pushback racking design accommodates GMA/CHEP style pallets when turned on the “Cut-Out” face. As carts require easy access to the fork, here, the front ties of the cart are dropped to make the cart surface level. 

5. Heavy Duty Systems

For heavy-duty systems, pushback designs must be able to handle at least 3000 lbs. For loads above that, further modification must be made in the carts and rails so that the design can easily tolerate up to 5,000 lbs. Moreover, these designs can accommodate stockings from 2 to 6 pallets deep.

Advantages of Pushback Racking System

The advantages of pushback racking go beyond better space utilization. Here is a breakdown of the prominent benefits of using this efficient storage system: 

  • Maximum Space Utilization: The prime advantage of a pushback racking system is that it allows excellent use of space. Whether the space is vertical or a bit congested, the pushback racking system allows the storage of multiple pallets in the same lane, reducing the number of aisles in the warehouse.
  • Enhanced Selectivity: Other than space maximization, easy access to the desired goods is equally important. In a pushback racking system, each level stores a separate SKU, which means goods can be retrieved easily without emptying the whole bay. 
  • Cost Saving: Compared to other storage systems, pushback design requires minimum labour as it requires lesser manual handling and forklift travelling within the warehouse. Not to mention, storing multiple pallets in a single lane reduces the frequent need for restocking and replenishments. 

What is the Cost of Pushback Racking?

Pricing of the pushback racking system may vary depending on rack height, lane depth, pallet weight, and configuration. Typically, the pushback racking system ranges between $120 to $250 per pallet.

However, there may be other factors affecting the cost; for instance, two deep pushbacks tends to be less expensive than four deep pushback, as deeper pushbacks require more steel. 

Why Should You Choose 3D Storage Solutions for Pushback Racking Systems?

Being a leading provider of pushback racking systems, 3D Storage Systems specializes in providing specially modified pushback racking designs for versatile warehousing needs. 

We deliver highly customized and practical storage solutions, including push-back racking, pallet flow racks, and carton flow racks, perfect for high-density storage. Contact us now and discuss your specific inventory management requirements. You can also request a free quote or drawing before proceeding further with your project.