Pallet stacking system

Types of pallet stacking systems

The pallet stacking system is an essential part of warehouse logistics. There are different types of stacking systems for pallets according to how products are stored and retrieved.

• Orbital and spiral pallet stackers

  Orbital and spiral pallet stackers are systems with a circular transport path that can be built either horizontally or vertically. Goods enter the system on a straight path and are released on a circular path. It is a compact way to change the direction of goods. These systems use motors and belts to move goods in any direction without having to turn the whole pallet.

• Automated pallet shuttles and robots

  Automated shuttles and robots are mobile devices that move pallets around the warehouse. They have the ability to move pallets further than just one aisle. These shuttles and robots make it possible for pallets to be transported to areas of stock that are not near where they are stored, reducing the need for items to be brought to the front of the inventory. This means that more items can be placed in the storage area, which makes it easier to store products and use space more efficiently.

• Flow racking

  Flow racking systems make use of roller tracks so that pallets can be moved by gravity. Pallets are pushed forward by the weight of the products on sloped tracks. They are stocked on the opposite side of the picking area through First In First Out (FIFO) method. This kind of pallet flow system is ideal for places where there is a lot of stock rotation and small batches of items need to be picked. Moreover, carton flow racks are similar to flow pallets but use containers and bins to store products.

• Stack and rack

  Stack and racks should be designed to make the most of vertical space and allow for easy access to all pallets. Usually, fork trucks or other material handling equipment is used to deposit and withdraw items. While stack racks are fixed storage facilities, rack systems have frames made of lightweight materials that can be folded when not in use. Selective racking is the best choice for warehouses that do not have a large number of pallets for each kind of product.

Specification & Maintenance

• Load Capacity

  Typically, flow racks have a load capacity of 50-200 kg per pallets. But some flow rack systems can have a capacity of up to 5000 kg if the roller diameter is large.

• Aisle Width

  Generally, the aisle width for a pallet flow system is 1.5 m-2.0 m. The exact width will depend on the overall dimensions of the rack.

• Height

  The height of a flow rack system can vary whenever a custom design is used. But in general, the heights are within 2.0 m-5.0 m.

• Number of carts

  The number of carts in the flow stacking system will directly affect the speed at which items can be picked and replenished. Usually, the carts are between 5-20.

• Material

  Some common materials for a flow rack are cold-rolled steel, stainless steel, aluminum alloy, etc. Material specifications can differ according to the particular features of each material.

Regular maintenance can help prevent untimely and costly breakdowns and extend the life span of the pallet stacking system. Here are some routine maintenance tips:

• Perform daily visual inspections on the flow rack system. Look for any signs of damages, such as misalignment, bent or broken components, etc.
• Take prompt actions to address issues discovered during the inspections. For example, if there is a damaged part, get it repaired or replaced immediately.
• Schedule routine cleaning for the flow rack. Dirt and other storage facility contaminants can shorten its lifespan and cause functional problems.
• Lubricate moving parts, like rollers or carts, to reduce friction and improve operating smoothness.
• Perform periodic checks on load bearing capacity. Warehouse managers should ensure that the flow rack's capacity is not exceeded. Otherwise, the system's structural integrity will be compromised.

Usage scenarios of pallet stacking systems

Pallet stacking systems provide efficient and organized storage solutions for various industries and sectors. Here are some common usage scenarios for pallet stacking systems.

• Warehouse and distribution centers

  Pallet stacking systems are commonly used in warehouse and distribution centers for stock management. The systems maximize storage capacity, make it easier to find and access goods, and boost productivity in areas where pallets are the standard unit of handling.

• Manufacturing facilities

  Pallet stacking systems organize raw materials, work-in-progress items, and finished goods for manufacturing facilities. Vertical and selective pallet stacks are used in the same way to optimize production efficiency, simplify workflows, and support just-in-time manufacturing.

• Retail and e-commerce

  Pallet stacking systems enhance inventory management, order fulfillment, and stock replenishment in supermarkets, hypermarkets, and online shopping platforms. Pallet racking systems, especially selective and drive-in/out racks, are widely used to support speedy picking and distribution operations.

• Cold storage and refrigeration

  Pallet stacking systems manage perishable goods and temperature-sensitive items in cold storage facilities and refrigerated warehouses. FIFO (first-in, first-out) flow racks or gravity flow shelves are commonly used to achieve proper stock rotation and maintain freshness.

• Food and beverage processing

  Pallet stacking systems are used to optimize storage capacity, streamline production processes, and maintain hygiene standards in facilities that make food and drinks. To sustain effective production, easy access, and proper stock rotation, they often employ clean room racks, selective racks, and flow racks.

• Automotive and aerospace

  Pallet stacking systems are typically used to manage components, assemblies, and finished vehicles in the automotive and aerospace industries. The systems increase production flexibility and efficiency by using commonly employed flow racks, AS/RS (autonomous storage and retrieval systems), and both simple and intricate automation systems.

• Pharmaceutical and healthcare

  Pallet stacking systems organize medical equipment, supplies, and pharmaceuticals in healthcare facilities such as hospitals, clinics, and pharmacies. The systems ensure accessibility, compliance, and efficient inventory management in places related to medicine.

How to Choose pallet stacking systems

Purchasing outside pallet stacking systems for sale can be an easy task when following a few tips. Determine the kind of materials the public works warehouse is made of. Warehouses constructed using sturdy and longer-lasting materials are the most ideal.

Consider purchasing warehouse stacking systems with shelves. Stacking systems with shelves maximize space, as items will be placed on shelves instead of just on the floor. Additionally, this will make it easy to retrieve items as shelves are at an easy reach.

Buy stacking systems that are suited for the size of items or pallets to be stacked. When items are unusually large, cumbersome, or heavy, it becomes a challenge to stack them. Hence, it is important to note the size and weight of items that are to be stacked and choose a stacking system that is suitable.

When items need to be accessed frequently, select a stacking system with shelves that are suited for manual handling. Furthermore, consider investing in a stacking system with additional security features when the items are valuable. Such systems will require locks to prevent unauthorized access.

Lastly, consider the number of pallets the stacker is required to handle on a daily basis. If the figure is quite high, it might be wise to invest in a more advanced and automated system.

Q&A

Q: What is the purpose of a pallet stacking system?

A: The main purpose of a pallet stacking system is to store pallets in a way that maximizes available space while maintaining efficient access to the stored goods.

Q: How does a pallet stacking system improve warehouse efficiency?

A: By maximizing storage capacity, facilitating easy access to pallets, and streamlining the order fulfillment process, pallet stacking systems improve overall warehouse efficiency and productivity.

Q: What are the limitations of pallet stacking systems?

A: The limitations of pallet stacking systems include the availability of floor space, weight and size limitations, access and visibility, the condition of the stored items, and theautomation budget.

Q: Can pallet stacking systems be used for irregular-shaped items?

A: Yes, pallet stacking systems can be used for irregular-shaped items but may require additional support or customization to accommodate those items securely.