Push-Back Pallet Racking

Push-back pallet racking is a high-density storage solution that maximizes warehouse capacity by eliminating interior aisles and allowing for up to five pallets deep per lane. Pallets are placed on carts or rollers along rails set at a slight incline. The system operates on a LIFO (last in, first out) principle, where forklifts push back existing pallets to create space for new ones. As goods are removed, gravity automatically advances the back pallets forward, maintaining access in a single working aisle.

Push-back racking systems are versatile but particularly suited for medium-turnover palletized goods managed via the LIFO method, especially when there are two or more pallets per SKU. They are also effective in facilities with fewer SKUs and pallets. Additionally, push-back racks excel in storing fast-moving consumer goods (FMCGs), enhancing loading and unloading efficiency. Overall, these high-density storage solutions are ideal for businesses looking to maximize available space and expand warehouse capacity.

The primary distinction between pallet flow and push-back racking systems lies in their inventory management strategies. Push-back racking operates on the LIFO (last in, first out) principle, as goods are accessed from the same aisle. In contrast, pallet flow racking utilizes separate aisles for loading and unloading, adhering to the FIFO (first in, first out) principle.

The push-back rack is a high-density storage solution that accommodates different SKUs in each lane. Forklifts operate from a single aisle, enhancing safety and efficiency by eliminating the need for maneuvers inside the structure. However, the system is limited in depth and height, typically allowing for five pallets deep and a maximum frame height of 40'. For greater capacity, Interlake Mecalux offers alternative solutions, such as the Pallet Shuttle system, which can reach storage lanes of up to 130' deep.

Interlake Mecalux’s push-back pallet racking uses carts and rails that allow up to 5 pallets per lane. When integrators are used, deeper lanes can be achieved.

The height limit will be set by the handling equipment, available space, and product weight. Interlake Mecalux manufactures frames up to 40' in height.

The beam width depends on the pallet dimensions and the number of pallets wide. For 40" wide pallets, three standard options are available: a 48" beam for 1 pallet wide, a 96" beam for 2 pallets wide, and a 144" beam for 3 pallets wide.

Pallets should be placed from the designated entry side, with the first pallet resting on the top cart. Subsequent pallets push the prior ones into the racking until the last pallet is positioned on the rails. For unloading, the process is reversed, allowing gravity to automatically fill the first pallet position.

In a push-back pallet rack, each storage lane within a bay operates independently from those above and below, allowing different SKUs to be assigned to each level. This offers a clear advantage over drive-in racking, where the same SKU has to be stored across all levels of each bay.

Theoretically, any forklift model can be utilized with push-back pallet racking systems, but certain factors must be considered. The forklift’s rigidity and strength will influence the number of pallets per lane. It is generally recommended that the forklift can push 4% of the total weight of the pallets being moved, excluding the pallet on the forks. For example, in a five-deep system with each pallet weighing 3,000 lbs, the forklift would need to exert approximately 480 lb of force (4% of 12,000 lb).