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Recently a Midwestern company, with multiple distribution facilities, contacted Senior Design Specialist, Jerry Fredrickson, to help it maximize pallet storage space in two of its warehouses.
In warehouse #2 the customer was currently utilizing two deep push back pallet rack along with standard selective pallet racks. This allowed staff to pick pallets efficiently, although the system was not maximizing the available space.
Jerry designed a new warehouse rack system that would maximize the storage density but still allow for selectivity. Jerry’s layout for the 400’ x 270’ warehouse consisted of the following: 1st Level Floor Stacking, 2nd Level Drive-In, and 3rd Level Push Back. This new system enabled the company to maximize the space in the warehouse while providing significant selectivity for staff.
During the design process, Jerry’s challenge was to work around a lot of building column interference. He divided the 88 bays of racking into two sections, which enabled him to avoid problems with the columns and minimize the loss of pallet positions. With the new design, Jerry also planned for more doorways to be added between the warehouses to make operations more fluid. The existing racking system did not go to waste – it was taken down and reassembled in the smaller of the two warehouses, saving the customer significant overall project costs.
As a result of the new design, 12,000+ pallets can now be stored in both warehouses and the building’s storage space has been increased by approximately 33 percent. Our installation team did a fantastic job and allowed ongoing operations to continue throughout the installation of the new racking system and relocation of the existing racking.