Push Back Racking: Super-Efficient High-Density Storage

Pros and Cons of Push Back Racking

Like any type of warehouse equipment, push back racking has its advantages and disadvantages.

Advantages

• High-density system holds up to 90% more stock than standard selective racks
• Offers up to five times more selectivity than drive-in racks
• Faster to load and unload than drive-in or drive-thru racking
• Each level and lane is independently accessible
• A single lane can accommodate a variety of SKUs
• Customizable and compatible with other types of pallet racks
• Low maintenance
• Forklifts don’t enter the structure, reducing risk of impact damage
• Needs only a single accessibility lane, allowing it to go up against a building wall

Disadvantages

• Not suitable for all types of inventory; loaded pallets must be heavy enough and stable enough to push back the other pallets in the lane
• Limited to six pallets deep
• More expensive than a comparable drive-in system
• Last-in-first-out system is not ideal for perishable inventory that will expire if stored too long

Push Back vs. Drive-In Racking

Push back racking and drive-in racking both offer high-density storage for last-in-first-out stock rotation. The two systems look similar, but there are several key differences.

• Drive-in racks use horizontal rails. A forklift has to drive into the rack structure to retrieve the pallets at the back of the lane. The rails of a push back rack are inclined toward the aisle, so gravity pulls each pallet forward as the one before it is removed.
• Drive-in racks are susceptible to damage caused by forklifts bumping into them. Because forklifts never enter a push back rack, the damage risk is greatly reduced.
• Push back racking is better suited to multiple SKUs. It offers three to five times the selectivity of a drive-in rack.

How Push Back Racking Works

To load a push back rack, a forklift places a pallet on the top cart of each lane. The forklift then gently pushes that cart back to expose the one underneath. The process continues until all the carts are used, then the last pallet is placed directly on the rails.

Who Should Use Push Back Racking?

Push back racking is ideal for facilities with:

• Little to no order picking
• Nonperishable inventory suited to last-in-first-out stock rotation
• High pallet counts with a limited number of pallets per SKU
• High turnover volume

Industries that enjoy great success with these racking systems include:

• Manufacturing
• Third-party logistics
• Automotive
• Aerospace
• Consumer goods

Structure and Dimensions

Most push back systems are made of structural pallet racks, though roll-form racking is also an option. The frame consists of uprights, diagonals, baseplates, and floor anchors.

Beams fit into punched holes in the uprights to provide lateral support. Rails are fixed to the beams with a slight incline toward the aisle – just enough grade for pallets to slide forward as the front pallet is removed. The rails extend the full depth of the storage lane and are equipped with either nested carts or rollers.

Backstops may be installed on the rails at the back of the lane so pallets aren’t accidentally pushed off the back of the rack. On the front of the lane, pallet guidance can be added to help forklift operators put down the pallet in the right spot.

Dimensions

• Push back racks can store pallets of varying sizes – they can even be customized to accommodate extra-long or extra-wide pallets.
• A rack can hold pallets up to six deep and four high.
• Standard cart capacity is 3,000 pounds. Heavy-duty carts are available to accommodate heavier loads.
• Standard rack dimensions follow conventional pallet sizes: 8 feet to 28 feet deep, with a 96-inch double-wide bay. Custom racks are available for non-standard pallet sizes.
• A standard push back rack is 16 to 20 feet tall. The appropriate height for a given location depends on the height of the ceilings, the strength of the uprights, and the reach of the facility’s forklifts.