High‑Density Pallet Storage Systems

Drive-In Racking

High-density pallet storage for bulk quantities of similar products.

Drive-in pallet racking stores pallets several positions deep in lanes. Forklift trucks enter the racking to place and retrieve pallets, so the layout needs fewer access aisles than conventional single-deep pallet racking. This can increase warehouse storage capacity where floor space is limited.

Drive-in racking is most efficient when you hold large quantities of the same product, as each lane is generally dedicated to one SKU. It commonly uses last-in, first-out (LIFO) stock rotation, so the last pallet loaded is the first one retrieved. It can suit bulk storage in food and beverage, cold storage, manufacturing and distribution warehouses, where storage density is more important than immediate access to every pallet.

If you’ve explored drive-in racking but need more flexibility to store different SKUs, a pallet shuttle system may be an alternative.

By storing pallets several positions deep and reducing the number of access aisles, drive-in racking can allow the same number of pallets to be stored in around 40% less floor space, depending on the warehouse layout and stock profile.

Double-Deep Pallet Racking

More pallet positions in each row, with access to two pallets deep.

Double-deep pallet racking places pallets two positions deep, usually using a specialist reach truck with extended forks to access the rear pallet. Compared with single-deep racking, it can increase pallet storage capacity while keeping familiar racking rows and access aisles.

It is often a good fit when you have multiple pallets of each product and want higher storage density without moving to deep-lane systems such as drive-in racking. Because the front pallet must be moved to reach the pallet behind it, double-deep storage works best when stock can be managed in pairs or batches and every pallet does not need immediate direct access.

By placing pallets two positions deep while retaining familiar rack rows and aisles, double-deep racking is able to hold the same pallet quantity in about 20% less floor space, where the layout and access requirements suit the system.

Pallet Shuttle Systems

A motorised shuttle moves pallets through deep storage lanes.

A pallet shuttle travels on rails inside the racking lane to move pallets into storage or bring them back to the access point. Forklifts position the shuttle and load or retrieve pallets, reducing the need for trucks to enter the lanes.

Like drive-in racking, pallet shuttle systems store pallets in deep lanes to make efficient use of space. They offer more SKU flexibility: each lane and level can hold a different SKU, while maintaining high storage density. Because forklifts don’t need to travel into the lanes, shuttle systems also reduce in-rack forklift movement and the risk of damage to the racking.

By using a shuttle to move pallets through deep storage lanes while keeping forklifts out of those lanes, a pallet shuttle system can store the same number of pallets in roughly 15–20% less floor area, depending on the system configuration.

Mobile Pallet Racking

High-density storage with an access aisle that opens where needed.

Mobile pallet racking is installed on powered bases that move along floor rails. Instead of having a fixed aisle between every row, the system opens an aisle where access is needed.

By moving rack rows to open an aisle only when needed, mobile racking can fit the same pallet quantity into up to about half the floor space, while still providing access to stored pallets.