Introduction to Warehouse Racking Systems in Food Industry
In industrial and food manufacturing settings, warehouses serve as critical hubs for storing raw materials, finished goods, and packaging materials before processing or distribution. In the food processing industry, warehouses must be designed to accommodate various storage requirements—such as dry storage and cold rooms—depending on the nature of food products.
An efficient warehouse racking system enables vertical stacking of goods in horizontal rows, optimizing both space utilization and material handling efficiency. Effective racking system design plays a key role in food safety compliance, inventory control, and overall operational excellence in modern food factories.
Key Factors in Designing a Warehouse Racking System
1. Available Space
Assessing vertical and horizontal space helps determine rack configuration and storage density, crucial for food factory design.
2. Pallet Dimensions and Load
Racking systems must match pallet size, material, and weight. Choosing the correct load-bearing structure is critical for safety and reliability.
3. Volume of Goods
Understand the throughput of food manufacturing operations—both inbound and outbound—to avoid overcapacity or underutilization.
4. Number of SKUs
High SKU variety requires prioritizing selectivity, while bulk storage benefits from higher density racking systems.
5. Budget and Operating Costs
A long-term cost-benefit analysis must include manpower efficiency, compliance with food safety norms, and space utilization.
6. Inventory Management Method
Different systems support FIFO (First-In-First-Out) or LIFO (Last-In-First-Out) practices, affecting the food supply chain's freshness and traceability.
1. Types of Warehouse Racking Systems
There are numerous types of racking, each with its own set of advantages in terms of accessibility or storage capacity. The most common type of racking based on storage density and selectivity are described here:
Selective Racking: The most common type for food distribution centers with diverse SKUs. Offers:
- 100% selectivity
- Cost-effective setup
- Compatibility with FIFO
Subtypes:
- Roll Formed Pallet Rack – Lightweight, teardrop design
- Structural Pallet Rack – Heavy-duty, bolt-connected
Double Deep Pallet Racking : Ideal for increasing storage density in limited space.
- Requires deep-reach forklifts
- Increases capacity by 40–60%
- Reduces selectivity
Very Narrow Aisle (VNA) Racking : Suited for high-density storage in compact spaces.
- Uses side-loading and standard forklifts
- Maintains full selectivity
- Ideal for food warehouses with premium space constraints
This racking type necessitates the use of two sets of equipment for loading and unloading. The first is a side-loading forklift, and the second is a standard forklift used to transport goods from the palletizing station to the base of operations.
Drive-In and Drive-through Racking: Used in bulk food storage of homogeneous products.
- Drive-in: LIFO model
- Drive-through: FIFO model
- Eliminates multiple aisles
- Excellent for cold storage and long-term preservation
Drive-in racking has only one access aisle where the last load-in is the first load-out (LIFO); drive-through racking has an entrance and exit and the first load-in is the first load-out (FIFO). This is the best solution for storing homogeneous products with a large number of pallets in a warehouse where space utilization trumps selectivity.
Push-Back Racking: Best for high-turnover environments using the LIFO method.
- Higher storage density
- Suited for packaged foods and ready-to-distribute products
- Available with shuttle or roller movement systems
Shuttle Racking: Automated solution for large-scale food factories.
- Supports both FIFO and LIFO
- Ideal for cold storage, beverage plants, and meat processing facilities
Flow racking system: Gravity-based system supporting FIFO.
- Continuous movement through inclined lanes
- Best for fast-moving SKUs
- High-density, low-maintenance system for food logistics
Conclusion
Choosing the ideal warehouse racking system depends on layout, storage goals, SKU variety, handling frequency, and food safety requirements. Food processing consultants and engineering experts play a crucial role in selecting racking systems aligned with regulatory norms, cost-efficiency, and performance needs.
Whether it's selective racking for diverse SKUs or pallet shuttle systems for cold storage, the goal is to ensure streamlined operations, regulatory compliance, and maximum space utilization in food industry warehousing.
References
1. https://www.iqsdirectory.com/articles/storage-rack/warehouse-racking.html
2. https://www.ar-racking.com/en/storage-systems/automated-warehouses/pallet/pallet-shuttle
3. https://www.interlakemecalux.com/blog/flow-racking-systems-types
4. https://www.adaptalift.com.au/blog/2011-08-24-what-is-selective-racking-warehouse-racking-guide-part-2
5. https://www.southwestsolutions.com/ssg/compact-pallet-rack-storage-systems/
6. https://www.mbaskool.com/business-concepts/operations-logistics-supply-chain-terms/18084-fifo-first-in-first-out.html
7. https://rebstorage.com/our-products/rack-products/drive-in-and-drive-through-rack/
8. https://www.work-fit.com/blog/warehouse-pallet-rack-safety-101
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