Maximize Storage with a Drive In Drive Through Racking System

In the constant pursuit of warehouse efficiency, space is your most valuable asset. For businesses storing large quantities of similar products, traditional shelving with multiple aisles can be a wasteful use of this asset. This is where high-density storage solutions shine. A drive in drive through racking system is a robust, forklift-based storage method designed to maximize cube utilization by minimizing aisle space. Bari Engineering specializes in designing and installing these critical systems, helping businesses achieve remarkable storage density and operational flow, whether using a LIFO or FIFO approach with drive through pallet racking.

What is Drive In Drive Through Racking?

Drive in drive through racking is a high-density storage system where pallets are stored in continuous rows, with the rack structure itself supporting the pallets on rails. Unlike selective racking, forklifts actually drive into the rack structure to place and retrieve pallets. This eliminates the need for multiple aisles, creating a solid block of storage.

The key distinction lies in the system's configuration:

  • Drive-In Racking: This is a Last-In, First-Out (LIFO) system. It has an entrance on one side only. Forklifts drive in, deposit a pallet on the rails, and reverse out.

  • Drive-Through Racking: This is a First-In, First-Out (FIFO) system. It has an entrance on one side and an exit on the other, allowing for a continuous flow of goods.

Both configurations fall under the umbrella of drive through pallet racking in common industry parlance and offer significant space savings over traditional alternatives.

The Structural Design of the System

The strength and functionality of this system come from its unique design, which is engineered for both stability and accessibility.

Upright Frames and Rails

The system uses heavy-duty upright frames to create the storage bays. Instead of beams, specially designed rails are installed at each storage level. These rails guide the forklift and support the pallets, allowing them to be slid into position deep within the rack.

The Guide Rails and Entry Protection

Critical to safety and functionality are the guide rails at the entrance and throughout the lane. These rails ensure the forklift enters the structure correctly and prevent damage to the upright frames. Corner guards and column protectors are essential accessories to absorb impact and maintain the system's integrity.

Key Differences: Drive-In (LIFO) vs. Drive-Through (FIFO)

Choosing between a LIFO or FIFO configuration is a crucial decision that depends entirely on your inventory profile.

Drive-In Racking for LIFO Inventory

This configuration is ideal for products that are not time-sensitive. Examples include archived documents, seasonal items, or bulk raw materials where the last pallet stored will be the first one retrieved. While highly space-efficient, it can lead to longer retrieval times for pallets stored at the back of the lane.

Drive-Through Racking for FIFO Inventory

This design is perfect for goods with expiration dates or those that need to be rotated in a specific sequence, such as food, beverages, or pharmaceuticals. Pallets are loaded from one side and retrieved from the other, ensuring proper stock rotation and consistent product flow.

Major Advantages of Implementing Drive Through Pallet Racking

Adopting this high-density solution provides tangible benefits that directly impact your warehouse's productivity and bottom line.

Exceptional Space Utilization

By consolidating multiple aisles into a single, shared access aisle, a drive in drive through racking system can increase storage capacity by up to 75% compared to selective pallet racking. This allows you to store a much larger volume of goods without expanding your building's footprint.

Reduced Operating Costs

The high density directly translates to lower cost per pallet position. You gain more storage within the same square footage, which can delay or eliminate the need for a costly facility expansion or relocation.

Ideal for Homogeneous Products

The system excels when used for a limited number of SKUs in high volume. It simplifies inventory management and is perfect for cold storage facilities or warehouses dedicated to storing a single type of product.

Utilizes Standard Equipment

Unlike some automated systems, drive through pallet racking operates with standard, counterbalanced forklifts. This means you may not need to invest in specialized, expensive equipment to use the system effectively.

FAQ: Your Drive-In Racking Questions Answered

Q1: What type of forklift is required for this system?
A standard, maneuverable counterbalanced forklift is typically used. The operator must be highly skilled, as navigating within the rack structure requires precision. The forklift should be in excellent condition to minimize the risk of breakdowns inside a lane.

Q2: Is this system safe for my products and operators?
Safety is paramount. While the system is very safe when used correctly, it requires trained operators. The rack structure must be equipped with safety guides, guards, and impact protection. At Bari Engineering, we conduct thorough operator training to ensure safe practices.

Q3: Can I mix SKUs within the same lane?
It is strongly discouraged. For optimal efficiency and to prevent product confusion or damage, each lane should be dedicated to a single SKU. This ensures smooth operation and accurate inventory control.

Q4: How does drive-in racking compare to a pallet shuttle system?
Both are high-density solutions. Drive in drive through racking requires a forklift to enter the structure, while a pallet shuttle system uses a remote-controlled cart inside the lane, with the forklift remaining at the front. The shuttle system can be faster and safer but often comes with a higher initial investment.

Conclusion

A drive in drive through racking system is a powerful, cost-effective solution for businesses that need to maximize storage density for high-volume, homogeneous products. Whether your operation requires the simplicity of a LIFO drive-in system or the precise stock rotation of a FIFO drive through pallet racking configuration, Bari Engineering has the expertise to design and implement a solution tailored to your needs. By significantly increasing your storage capacity without expanding your footprint, this system offers a compelling return on investment. Contact Bari Engineering today for a consultation and let us help you drive efficiency into your warehouse operations.