by Vikas Choudaha, Senior Vice President and Business Head, Godrej Storage Solutions
As we witnessed a boom in e-commerce last year and with social distancing rules coming into effect, warehouses underwent a transformation to meet the changing demands. Different warehouse racking and shelving options that allow more space between the staff, enhance productivity, and maximize storage space became a key priority. The right kind of racking solutions in place can provide additional space in warehouses making optimum use of the space available without having to worry about building new facilities.
Racking systems are well-designed metal structures that support heavy goods that are carried in warehouses. Different types of racks are available that play a key role in the seamless operations in a warehouse. Having different racks help in systematic logistics and supply chain management ensuring timely delivery of goods. With the radical increase in demand for warehouse usage, storage system facilities have adapted to the growing needs to provide dynamic services to various sectors.
Here are some types of warehouse racks, which can be used to perform different functions.
Selective Pallet Racking is the simplest and economical racking system, which allows 100% accessibility to each pallet. This racking is suitable for large variety of SKU's irrespective of quantity. This system offers a unique quality of selective accessibility, effectively allowing one to store and retrieve various SKUs in a highly independent, organized, and systematic manner. This also ensures that a single pallet can be accessed without upsetting any other pallet on the system. The versatility that Selective Pallet Racking offers coupled with the right set of accessories can be an ideal solution for sectors as diverse as aerospace to FMCG and e-commerce.
Very Narrow Aisle (VNA) Pallet Racking is a compact version of selective pallet racking that takes up lesser floor space. The system is made compact by narrowing the aisles which helps save around 40% space. However, this type of racking requires special VNA equipment that can be operated in aisles less than 2 metres and can even go up to 18 m high. This equipment needs special guides like mechanical rails or electrical wires. The system is best suited for operations that demand faster throughput and can accommodate more pallet positions by utilising vertical space in the warehouse.
Mobile Pallet Racking is a modernized storage solution where the racking structure is fixed on movable chassis. This system eliminated the need for unproductive aisles which open only when accessed by remote control. This system can offer double the storage capacity as that of selective pallet racking, while still offering 100% selectivity. The system is suitable for large varieties of SKUs in any industry. However, its compact nature makes it the best choice for cold stores.
ASRS Racking is a highly automated storage solution where the pallets are stored and retrieved by stacker cranes with telescopic arms. These stacker cranes run on a fixed rail and can move in between aisles through transfer car or curving rails. In this system, the inventory management control is completely automated by integrating with WMS. ASRS systems are used in factory attached warehouses for Raw material and Finished goods storage and can be most commonly found in chemical and pharma industries. These systems can be designed to be single deep or double deep depending on SKU variety. ASRS systems utilize the vertical space of the warehouse and can be integrated into Rack supported warehouses, eliminating the need for buildings.
Double Deep Pallet Racking is a simple racking system, that offers 20% more density with 50% selectivity. It is suitable where SKU variety is not high and ideally two pallets of same SKUs are to be kept one behind the other. This comes with several benefits including vertical and horizontal scalability, adaptability to varying pallet and load heights, and wide range of beam and uprights that offer optimal solution for any pallet size / load.
Pushback Racking is another form of compact storage system where pallet loading is done by pushing the first pallet back. Unloading is enabled by gravity for which the pallet carts are fitted with rollers. In this system, loading and unloading of pallets is from the same end. Hence, this type of system operates on LIFO (Last In First Out) principle, which makes it an ideal choice for batch productions of lesser variety of SKUs.
Drive in Pallet Racking is a compact system that offers 80-120% more density than selective pallet tracking, conceptualized for managing few varieties of SKUs produced or dispatched in batches. As evident from the name, Material Handling Equipment like reach trucks drive inside the racks to access the pallets. Each storage bay is one pallet wide. This system is suitable for industries involved in batch production and batch dispatch.
Shuttle Pallet Racking is a semi-automated remote-controlled storage system, with radio shuttle on racks to swiftly carry the pallets. The system can be configured to suit LIFO/FIFO operations and is suitable to accommodate more varieties of SKUs in comparison with drive-in racking. This solution offers higher throughput while improving storage density.
Pallet Flow Racking is a dense storage system that utilises maximum storage cube. As the name depicts, the pallets flow from one end to another by force of gravity on metal rollers moving and the loading-unloading process becomes easy. This system is designed to store pallets of multiple high and multiple deep. Each level shall be dedicated to one type of SKU only. This racking is suitable for batch production / storing homogeneous products and expiry date for SKU is critical. This racking has pallet loading on one end and unloading on the other end.
Cantilever Racking is specially designed to store long and irregularly shaped items, such as metal beams, pipes, moulding, wooden crates, etc. Depending on the height and weight of the merchandise, light or heavy-duty racking options are available. Cantilever racking is usually built to withstand harsh weather conditions in an exposed environment.
One can choose warehouse racking system based on the variety of units, capacity, throughput required and many such factors. As technology is advancing, different solutions are being introduced to ease processes. Smart storage ideas are in with cutting-edge techniques and effective solutions. A warehouse management system can also be much more effective with the right kind of training in automated solutions, empowering employees to be more efficient even with a high intensity of work.
Another important aspect to consider here is the upgradation, modification, or relocation of storage systems in line with one’s evolving business needs. Racking systems should be modularly designed that enables easy expansion for future needs. Rack Lifecycle services can help businesses seamlessly meet their evolving warehousing needs post-installation and reduces capital investment by extending the life of the storage system. Regular inspection of the storage system enhances warehouse safety, ensuring both man and material safety. For instance, Warehouse Rack Safety Audit can significantly improve the chances of preventing major warehouse damage that might lead to potential man or material loss. These audits help in identifying risks and bridging the gap in achieving operational safety goals.
Rack relocation involves meticulous planning for seamless transition without affecting your operations right from orderly dismantling at the existing location, proper packaging to ensure material reaches in perfect condition & then safely re-install the storage system with corrective modification & add-ons at the new location.
As manufacturers are busier than before, planning ahead is of prime importance. In the changing landscape of warehouses, businesses are taking a look at rack design and safety as an integral part of operations as they prepare for the future. Innovation is focussed on establishing safe and efficient handling of goods by means of automation.
