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Drive-In/Drive-Thru Pallet Racking

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Driving Efficiency: The Benefits of Drive-In/Drive-Thru Pallet Racking

In the world of warehousing and storage, space optimization and efficiency are paramount. Drive-In and Drive-Thru Pallet Racking systems are revolutionizing how businesses manage their inventory.

Drive-in/drive-thru pallet racking systems offer a denser solution for warehouses storing large quantities of a low variety of SKUs. As the name suggests, drive-in/drive-thru systems allow fork truck operators to enter into the depth of the system. By configuring this type of design the need for space-demanding aisles for fork truck movement is greatly decreased. The trade-off for this increased density lies in the decrease in the ability to rotate stock as the first pallet loaded into a drive-in pallet rack system will be the last pallet to be unloaded.

As with most Rack Builders storage solution offerings, drive-in/drive-thru rack utilizes many of the same components as selective pallet rack but by changing to feature a few unique components allows pallets to be more densely loaded. Some key pieces that are added to the system include support rails and typically, vertical and horizontal bracing. The addition of these components allows drive-in rack systems to compare very competitively on a price per pallet position comparison to more simplistic storage systems. Both system types have their advantages but there are some points to be aware of when comparing these systems to more conventional, selective pallet racking.

Advantages of Drive-In and Drive-Thru Pallet Racking:

  1. High-Density Storage: Drive-In and Drive-Thru Pallet Racking offer high-density storage solutions, making them ideal for businesses looking to maximize their storage space. By utilizing both vertical and horizontal space efficiently, you can significantly increase your storage capacity without expanding your warehouse footprint.
  2. Selective Accessibility: Despite their high-density nature, these systems provide selective access to individual pallets. Whether you opt for Drive-In or Drive-Thru racking, you can access products in a Last-In-First-Out (LIFO) or First-In-First-Out (FIFO) order, depending on your inventory management needs.
  3. Ideal for Bulk Storage: If your inventory includes large quantities of the same SKU or seasonal items, Drive-In/Drive-Thru racking is perfect. These systems are designed for storing pallets of the same product, allowing you to efficiently manage bulk quantities.
  4. Space Optimization: By eliminating the need for multiple access aisles, Drive-In and Drive-Thru systems optimize your storage space. You'll have more room for storage racks, and your warehouse layout becomes more efficient.
  5. Streamlined Handling: With Drive-In and Drive-Thru racking, you can load and unload pallets using the same entry and exit point. This minimizes the need for forklifts to travel long distances, which not only saves time but also reduces the risk of accidents in busy warehouse environments.
  6. Adaptability: These racking systems are highly adaptable and can be customized to your specific requirements. Whether you're storing varying pallet sizes, different product weights, or need specific configurations, Drive-In/Drive-Thru racking can be designed to suit your inventory perfectly.
  7. Cost-Efficient Solution: Despite their many advantages, Drive-In/Drive-Thru racking is often cost-effective. The initial investment can lead to substantial long-term savings through improved storage efficiency and reduced labor costs.
  8. Enhanced Safety: Safety is paramount in any warehouse operation. Drive-In/Drive-Thru racking systems come with safety features such as guide rails and reinforced pallet rails, reducing the risk of accidents and product damage.
  9. Minimal Maintenance: These racking systems are known for their durability and low maintenance requirements. This translates to fewer disruptions due to repairs and more uptime for your warehouse operations.

Drive-In and Drive-Thru Pallet Racking offer a winning combination of high-density storage, selective accessibility, adaptability, and cost-efficiency.

Whether you run a distribution center, manufacturing facility, or retail operation, these racking systems can optimize your storage space, enhance inventory control, and elevate overall operational efficiency.

Drive-In versus Drive-Thru Pallet Racking

The difference between drive-in and drive-thru pallet rack systems is whether the system can be entered from a single side or if both sides can be entered by fork trucks. At their core they share a very similar design structure: trusses are configured in a series, with rails that extend the depth of the system to create a wealth of storage for pallet loads. This dense configuration allows for drive-in & drive-thru racking systems to reach impressive depths – although 2 to 10 pallets deep are the most typical system sizes.

Drive-in systems gain their rigidity from an “anchor bay” – which is essentially a selective bay of racking. This anchor bay resides at the rear of the racking structure which makes it impossible for trucks to get through. Whereas the front column connections to rails use arms that protrude horizontally into the bays, the two rear column positions sport structural beams on which the rails sit. This anchor bay allows for the front column locations to do without typical beams due to the rigidity of the structure itself. In deeper rack systems, horizontal (affixed to the top of the rack structure) and vertical (affixed to the rear of the rack structure) bracing provides a method for loading to travel to the anchor bay, which is essential in ensuring loading is adequately controlled.

Drive-thru racking systems offer a bit more flexibility in loading and unloading product from the rails because there are two points of access from both sides of the system. These systems do however require a bit more engineering on RBI’s part being that there are several different ways to accomplish system structural rigidity. For example:

By utilizing internal anchor bays, the drive-thru storage system becomes what can be described as a two-sided drive-in system. Fork trucks can still enter from either side of the system but three internal column locations will utilize beams and bracing to gain the required support.

By utilizing bracing bays, the drive-thru rack system gives up access to some bays (reducing the possible pallet positions) but still allows for both ends to be accessed in all adjacent bays. Fork trucks will be unable to enter in some of the bays at all due to the use of beams and bracing throughout, but will still be able to use adjacent bays as true drive-thru bays.

Drive-in racking systems are more common as they can easily be positioned with their back to a wall, eliminating a need for an aisle to access on the rear side, which can save quite a bit of aisle space. There is generally less cost for drive-in systems as they do not require fully braced bays or three columns of beams/bracing. There is also less risk as the system presents a more uniform system to fork truck operators.

As fork trucks are driving into the storage system in either drive-in or drive-thru, there is a greater risk of rack/truck interaction. RBI will design features to negate some of this possible damage by providing custom products such as in-line truss rub rails, floor-mounted angles, or rack-mounted guides.

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The Push-Back & Drive-In Hybrid Rack System

Drive-in racking systems can also be implemented with overhead push-back rack to allow for easier flow through the system. The floor would act like typical drive-in rack while the rail levels typically used on standard systems would be switched in place for push-back beams, rails, and carts. This allows for palletted material to be deposited as a double stack on the floor or for rapid movement while also allowing product above to be accessed via the first pallet position like one would with selective racking.

Ready to explore the potential of Drive-In/Drive-Thru Pallet Racking for your warehouse? Contact us today to discuss your storage needs and discover how these systems can transform your storage space.