HIGH DENSITY STORAGE, RAPID STOCK RETRIEVAL
Live pallet racking is a high density storage system designed for rapid loading and unloading of pallets.
Also known as gravity flow racking, live pallet racking is commonly used to store perishable goods. Pallets are loaded into dedicated lanes of inclined gravity rollers so that when a pallet is retrieved from the pick face, subsequent pallets automatically roll forwards into position.
Two types of live pallet racking are available to suit different operating methods, FIFO and LIFO. FIFO stands for, first in, first out. LIFO stands for, last in, first out. Both types of live pallet storge use inclined gravity rollers to ensure a pallet is always available at the pick face. Pallet speed is regulated by brakes fitted within the roller tracks for operator safety.
Live pallet racking:
Aisle width – to suit handling equipment
Handling equipment – standard counterbalance.
FIFO Pallet Racking
FIFO is designed for efficient stock rotation of highly perishable goods such as fresh foods.
Pallets are loaded into lanes at one end of the rack and pallets retrieved at the other. This ensures the oldest stock is always picked first.
FIFO pallet racking achieves up to 80% space utilisation. A large volume of pallets can be stored within each lane requiring just one aisle for loading and one aisle for picking. FIFO is the ideal pallet storage system to maximse warehouse capacity, with goods receiving and despatch processes separated by the racking installation.
Aisle width at the loading and pick face is configured to suit the handling equipment in use. Standard counterbalance forklifts are well-suited to FIFO pallet racking, making it the ideal choice to avoid additional investment in equipment.
LIFO Pallet Racking
LIFO pallet racking has just one loading and unloading point. LIFO stands for, last in, first out.
Often referred to as ‘push-back racking’, forklift operators simply push pallets into roller lanes. LIFO is used bulk storage of fast moving goods, especially where storage space is restricted.
Ideal for storing large volumes of homogenised goods, accessible by a single pick face, LIFO delivers rapid handling times. Similar to double deep pallet racking, this pallet storage system offers maximum capacity utilisation, requiring just one aisle for forklift access.
This bulk storage solution has the capacity to hold up to 6 pallets per lane. Offering the same benefit as FIFO, conventional forklift trucks can be used to handle goods in a LIFO racking system to avoid equipment costs.
Advantages of Live Pallet Racking
The characteristics of live pallet racking racking make it an attractive choice for bulk, high throughout operations and perishable goods distribution:
- Fewer aisles - greater stock holding capacity
- Reduced manoeuvring - rapid stock handling
- Lower handling risks
- Automated stock rotation - LIFO
- No forklift traffic interference - LIFO
- Fitted with safety features e.g., roller brakes
- Accessible with standard counterbalance forklift.
Live pallet racking is ideal to meet challenges in several key sectors:
Perishable goods
- LIFO supports precise stock rotation of goods with an expiration date
- Ideal for the food, pharmaceutical, and cosmetics industries
Manufacturing
- Live pallet racking is the ideal intermediate storage solution between process areas
- Efficient solution to maintain a continuous flow of stock for assembly.
Wholesale Distribution
- Rapid stock access is ideal for fast loading and unloading of vehicles
- Suitable for cold storage facilities
- Safe and efficient flow of goods.
Design and Installation
As a single supplier for all storage needs, Prodek offer a fast and hassle-free service.
From design to installation, Prodek work to deliver maximum revenue per cubic metre. Experienced engineers draw on a wealth of knowledge for every racking installation, identifying risks, opportunities, potential bottlenecks and pinch points, for ultimate operational efficiency.
A live pallet racking installation begins with a site survey. Prodek engineers assess operational parameters and business objectives, to deliver the perfect fit, every time. Prodek take care of Building Regulations applications, where required, removing a layer of complexity for customers
- Survey and design
- Building Regulations
- Project management
- Manufacture and installation
- Rack inspections
Racking Inspections
The use and ownership of a racking installation falls under the legal obligations of Provision and Use of Workplace Equipment Regulations (PUWER) and The Health & Safety at Work Act 1974.
Owners are required to carry out annual racking inspections to ensure equipment is safe for operators to use.
A racking inspection will identify any structural damage, classifying it as either amber or red. Racking identified as damaged will need to be replaced, with severely damaged equipment taken out of use immediately.
Prodek SEMA qualified racking inspectors provide a full report, detailing the nature and location of any damaged and non-compliant racking. Prodek offer a range of racking accessories, including Rack Armour upright protectors, to reduce the risk of impacts causing significant structural damage.
Additional Services
Live Pallet Racking (FIFO) – FAQ’s
What is Live Pallet Racking (FIFO)?
Live Pallet Racking (FIFO) is a high-density storage system designed for the rapid loading and unloading of pallets. FIFO stands for “First In, First Out,” emphasising efficient stock rotation.
How does FIFO differ from LIFO in Live Pallet Racking?
FIFO ensures that the oldest stock is picked first, promoting efficient stock rotation. In contrast, LIFO (Last In, First Out) has a single loading and unloading point, often referred to as ‘push-back racking,’ and is suitable for bulk storage of fast-moving goods.
What are the advantages of using FIFO in Live Pallet Racking?
FIFO offers up to 80% space utilisation, making it an ideal choice to maximise warehouse capacity. It requires just one aisle for loading and one for picking, reducing maneuvering, and is particularly efficient for the storage of perishable goods.
How does Live Pallet Racking contribute to greater stock holding capacity?
Live Pallet Racking (FIFO) minimises the need for multiple aisles, allowing for a greater stock holding capacity within the available space. This makes it a space-efficient solution for warehouses and distribution centers.
What types of goods are suitable for Live Pallet Racking (FIFO)?
FIFO is particularly suitable for perishable goods such as fresh foods, as it supports precise stock rotation. It is commonly used in industries like food, pharmaceuticals, and cosmetics where maintaining product freshness is crucial.
Can Live Pallet Racking be used in manufacturing processes?
Yes, Live Pallet Racking serves as an ideal intermediate storage solution between process areas in manufacturing. It facilitates a continuous flow of stock, contributing to the efficiency of manufacturing operations.
What are the safety features of Live Pallet Racking?
Live Pallet Racking is fitted with safety features such as roller brakes to regulate pallet speed for operator safety. This minimises handling risks and ensures the secure storage and retrieval of pallets.
How is the aisle width determined in Live Pallet Racking?
The aisle width in Live Pallet Racking is configured to suit the handling equipment in use. Standard counterbalance forklifts are commonly used, and the aisle width is adjusted accordingly to accommodate efficient loading and picking.
Does Live Pallet Racking support automation?
Yes, Live Pallet Racking, especially in a FIFO configuration, supports automated stock rotation. This contributes to operational efficiency by reducing manual handling and ensuring a systematic flow of goods.
How does Prodek ensure the success of a Live Pallet Racking (FIFO) installation?
Prodek conducts a thorough site survey, considering operational parameters and business objectives. Our SEIRS accredited team manages the entire process from design to installation, ensuring maximum revenue per cubic meter and compliance with Building Regulations.
For professional Live Pallet Racking design and installation, contact Prodek today.
What are the advantages of using Live Pallet Racking (FIFO)?
The benefits include improved stock rotation, reduced product spoilage, increased picking efficiency, and better space utilisation. Additionally, it minimises the risk of obsolete stock as older products are automatically brought to the front for retrieval.
What industries commonly use Live Pallet Racking (FIFO)?
Industries such as food and beverage, pharmaceuticals, and manufacturing often utilise Live Pallet Racking (FIFO). Any industry with products that have a limited shelf life or specific storage requirements can benefit from this system.
Can Live Pallet Racking (FIFO) be customised for different warehouse sizes?
Yes, Live Pallet Racking (FIFO) systems can be customised to fit various warehouse sizes and configurations. The system can be designed to accommodate different pallet sizes and weight capacities.
Are there safety considerations for Live Pallet Racking (FIFO)?
Safety is paramount. Regular inspections, proper personnel training, and adherence to weight capacity guidelines are essential. Safety features such as brakes and speed controllers are often integrated into the system to prevent accidents.
Can Live Pallet Racking (FIFO) be integrated with other warehouse management systems?
Yes, Live Pallet Racking (FIFO) can be integrated with other warehouse management systems, including inventory tracking and order management software. This integration enhances overall warehouse efficiency.
What maintenance is required for Live Pallet Racking (FIFO)?
Regular maintenance, including inspections of rollers, brakes, and overall system integrity, is crucial. Any damaged or worn components should be promptly repaired or replaced to ensure the system’s smooth operation.
How does live pallet racking contribute to sustainability?
By promoting efficient stock rotation, Live Pallet Racking (FIFO) helps reduce waste and minimise the disposal of expired or obsolete products. This contributes to sustainability by optimising inventory management and minimising environmental impact.