Optimising space, safety and warehouse logistics
Choosing the right warehouse racking is essential to designing a storage system that supports efficient warehouse operations. The wrong solution can create bottlenecks, slow down material handling and, in the worst cases, put operator safety at risk.
With a wide range of storage solutions available, selecting the right racking system requires a careful assessment of specific technical criteria to maximise space utilisation and maintain efficient material flows.
Material flow and unit load analysis
Before selecting a racking system, it is essential to assess what it will need to store and how goods will be handled. These two factors shape the entire storage infrastructure.
- Goods and load carriers: Will you be storing goods on standard Euro pallets, loose small items, or long, bulky products such as pipes and panels? Establishing the exact weight and dimensions of each unit load, including both the goods and their supporting carrier, is the first step in choosing the right racking system.
- Installation environment: The conditions at the installation site play a key role in determining the most suitable racking solution. Floor characteristics influence the choice of anchoring systems, while outdoor installations require consideration of wind loads and corrosion risks. Available headroom beneath roof beams, structural columns and fixed services such as sprinklers, lighting and pipework also determine the warehouse layout and the maximum racking height.
- Material handling equipment: Aisle width must be tailored to the handling equipment in use, taking into account each truck’s turning radius and maximum lift height. This applies to counterbalance forklifts, reach trucks and trilateral trucks.
Main types of industrial racking systems
Every warehouse has its own operational requirements. Here are the most widely used racking systems and their specific applications:
- Adjustable pallet racking (APR): The most versatile solution, providing direct access to every pallet. Ideal for warehouses handling a wide variety of stock-keeping units (SKUs).
- Drive-in and drive-through racking: These systems eliminate the need for individual access aisles within the racking, maximising storage density. Drive-in racking has a single access point per lane and operates on a LIFO (last in, first out) basis, making it ideal for slow-moving or non-perishable goods. Drive-through racking is accessible from both ends, allowing FIFO (first in, first out) stock rotation, making it better suited to faster-moving goods or products with an expiry date.
- Gravity flow racking (flow rack): These systems use inclined roller tracks to move unit loads automatically towards the picking face. They ensure FIFO (first in, first out) stock rotation mechanically, without operator intervention. Available for both pallets and cartons or boxes, they are particularly well suited to perishable goods and products with a short shelf life.
- Cantilever racking: The preferred solution for storing long loads. With no front uprights, it provides easy access to items such as bars, metal profiles and timber.
- Mobile racking systems: The racking units are mounted on movable bases that travel along floor rails, eliminating fixed aisles and opening an access aisle only where needed. This maximises usable floor space while maintaining direct access to every storage location. Mobile racking is ideal for archives, spare parts warehouses, cold storage facilities and other environments where space is limited.
- Shelving and picking systems: Designed for manual goods handling, these systems are essential for e-commerce operations and spare parts warehouses. They can often be combined with mezzanine levels to make better use of vertical space.
Safety and applicable regulations
Safety is a legal requirement. Warehouse racking is considered work equipment and must therefore comply with Italian Legislative Decree 81/2008 and the applicable technical standards.
- UNI EN 15635: This standard covers the use and maintenance of storage equipment. It provides for regular inspections, at least annually, by a competent expert to identify damage and other issues and classify them according to the risk levels set out in the standard.
- UNI EN 16681: This standard specifies design requirements for adjustable pallet racking systems subject to seismic actions. Given Italy’s seismic risk, its provisions are relevant to all pallet racking installations, including existing systems.
- UNI EN 15512: This standard specifies the structural design requirements for adjustable pallet racking systems.
- UNI 11636: This standard defines the process of validation for use of a racking system throughout its service life. It also provides a methodology for assessing and identifying the operational condition of racking systems in use.
- INAIL – Technical Guide to the Selection, Use and Maintenance of Pallet Racking: This guide provides guidance on the selection, use and maintenance of static pallet racking in the workplace. It also outlines a methodology for assessing the risks associated with the use of this equipment and identifying and implementing appropriate preventive and protective measures.
Budget: assessing the total cost over time
A low purchase price does not necessarily mean long-term savings. When budgeting for warehouse racking, it is essential to consider the total cost of ownership, including underused storage space, longer order-picking times and recurring repair costs. The value of a racking system should be measured by the operational efficiency it delivers over time, rather than by its initial cost alone.
Trust Di Massa Srl
Designing an efficient warehouse layout requires specialist technical knowledge. Our team will analyse your material flows and recommend a solution tailored to your operational needs and safety requirements. Get in touch today to arrange a logistics consultation.