The Different Ways To Stack and Ship Pallets

Choosing the Right Pallet Racking System for Your Warehouse

Every warehouse has its own mix of products, turnover patterns, and space constraints. A high volume e commerce facility in Jacksonville will not store goods the same way as a regional building materials yard or a food grade distribution center. Because of this, pallet racking is not a one size fits all decision. The best system is the one that fits your product mix, flow patterns, and equipment, while giving you room to grow as your business changes.

Core Pallet Racking Options and When to Use Them

The systems below represent the primary styles that most operations rely on. Many facilities use a combination of several types in order to balance high density storage with fast accessibility for high moving items.

Selective Pallet Racking

Selective pallet racking is the most common and flexible racking style in use today. It provides direct access to every pallet, which makes it ideal for warehouses that manage a large number of SKUs, frequently change product lines, or support case level picking. Because every position is reachable without moving other pallets, this system works especially well in facilities that prioritize fast order fulfillment and frequent inventory rotation.

For operations that are still growing, selective racking is also easier to adjust over time. Beam levels can be reconfigured to fit new pallet heights, and additional bays can be added as volume increases. Many Jacksonville warehouses start with selective racking and later blend in higher density systems as their inventory mix becomes more predictable.

Drive In and Drive Through Racking

Drive in and drive through pallet racking systems are designed to maximize storage density for large quantities of similar products. Instead of having an aisle in front of every pallet position, forklifts drive directly into the rack structure to place and retrieve pallets that are stored several positions deep. This design reduces the number of aisles required and allows more product to be stored in the same footprint.

These systems are a strong fit for operations with a limited number of SKUs and high pallet counts per item, such as food production, cold storage, or building materials. Drive in is typically last in first out, while drive through can be configured with entry and exit points on different sides of the rack, depending on the flow of goods.

Push Back Pallet Racking

Push back pallet racking is an effective option for facilities that require higher density storage but still want more selectivity than drive in systems. Pallets are loaded from the front and sit on nested carts or rollers. When a new pallet is placed on the front position, it gently pushes the previous pallet backward. When the front pallet is removed, the pallet behind it moves forward.

This design is ideal for last in first out inventory strategies and for operations that store multiple pallets of the same SKU. Push back racking is often used in distribution centers that handle both full pallet and case picking, as it balances density with reasonably fast access.

Pallet Flow Racking

Pallet flow racking is built for first in first out inventory control. Pallets are loaded on the higher side of a gently sloped lane and move to the discharge end on gravity rollers or wheeled tracks. As each pallet is removed, the next one flows forward automatically. This style of system is especially popular for date sensitive or perishable products where proper rotation is critical.

Facilities that handle food, beverages, or other time sensitive inventory often rely on pallet flow lanes as part of their pick face to improve accuracy and reduce product loss. The combination of FIFO rotation and high density storage can significantly improve space utilization in these environments.

Cantilever Racking

Cantilever racking is designed specifically for long, bulky, or irregularly shaped items that do not sit neatly on standard pallets. Instead of traditional beams and uprights, cantilever systems use vertical columns with arms that extend outward to support the load. This open front design makes it easy to store and retrieve items like lumber, steel pipe, drywall, conduit, and sheet goods.

For operations that handle building supplies, industrial materials, or similar products, cantilever racking provides clear organization and faster access. It also reduces the risk of damage that can occur when long items are stacked improperly on the floor.

Double Deep Pallet Racking

Double deep racking increases storage density by placing two pallets in each position, one behind the other. This reduces the total number of aisles required while still preserving a relatively high level of selectivity. Forklifts with deep reach attachments are used to access the rear pallet positions.

This system is a strong fit for businesses that store multiple pallets of the same SKU but still want more direct access than they would get from drive in or drive through designs. It works particularly well in facilities that want to grow storage capacity without expanding the building footprint.

Mobile Racking Systems

Mobile pallet racking systems place racks on powered bases that move along floor rails. Instead of multiple fixed aisles, these systems create a single working aisle that can be opened wherever it is needed. This approach dramatically increases storage density in facilities where space is limited or very expensive.

Mobile systems are frequently used in cold storage environments, record storage rooms, and high value inventory applications where every square foot must be used wisely. With careful planning and safety controls, these systems offer high density storage while still allowing full access to all pallet positions.

Mezzanine Racking for Vertical Expansion

When floor space is fully consumed but ceiling height remains underutilized, mezzanine racking can be an effective solution. By building a structural platform above existing racks or shelving, businesses can create an additional level for storage, light assembly, or office space. This approach effectively doubles the usable area without the cost and complexity of a new building.

Mezzanine systems are particularly helpful for operations that want to keep all activity within a single facility while supporting growth. They also provide flexibility, since the layout beneath and above the mezzanine can be reconfigured as needs change.

Carton Flow Racking for Pick and Pack Operations

Carton flow racking uses inclined shelves and rollers to move cases or cartons from the loading side to the picking side. Workers always pull from the front, while replenishment takes place from the rear. This design creates a natural first in first out rotation and keeps the pick face fully stocked with minimal manual handling.

Facilities that rely heavily on case picking, such as e commerce fulfillment centers, food service distributors, and parts warehouses, often use carton flow lanes to support high volume order processing. When combined with the right pallet racking and freight strategy, these systems create a faster, more accurate pick environment.

For companies evaluating which system is right for their operation, understanding these core racking types is the first step. With proper planning, the right mix of pallet racking options can transform warehouse space into a safer, more efficient, and more scalable environment that supports long term growth.