How to Design efficiency Layout OF Warehouse Pallet Racking System

Finding a efficiency warehouse racking solutions? Someone’s suggestion or information from facebook,google,reddit,will tell you pallet racking is the best choice. Optimize operations, reduce costs, and improve productivity, that is the purpose why people choose the pallet racking system.

In some case,communicate with my clients, the common question is how can they built a high efficiency warehouse with pallet racking system. Read this guide to know essential steps to create a warehouse layout.

Assess Your Storage Needs

What is the first question for bulit a warehouse? That is ensure your storage needs. Before design warehouse layout,involves a strategic approach that aligns with the specific needs is very essential.

Space Utilization: Effective use of available space to maximize storage capacity.
Accessibility: Easy access to stored goods for efficient retrieval and dispatch.
Flexibility: The ability to adapt to changing storage requirements.
Safety: Ensuring a safe environment for both personnel and goods.

Choose the right pallet storage solution

This is some sample assoasion for your warehouse layout:

Logistic Warehouse (Heavy Duty Racking)

What is the important things of logistic warehouse? The answer is Storage turnover rate. The main challenges of logistics warehouses are to pinpoint the exact location of specific inventory items, the speed of loading goods on pallets, or the pallet jack for transporting items damaged during transportation.

Due to increase logistics warehouse storage turnover rate, drive-in racking system and some selective pallet rack space is the best choice. Drive-in rack can provide a high-density storage solution that is ideal for a large number of identical or limited SKUs. Logistics warehouses require last-in first-out (LIFO) storage systems for deep compression design and single-channel access. The fixed design space of the tray holder can be selected for special shape and weight inventory to prevent product damage.


E-commerce Warehouse(Carton Flow Racking)

The hotest warehouse in recent years is E-commerce wareahouse. With the development of international logistics and shopping platforms, e-commerce warehouses have increased the demand for storage shelves, which need to handle large numbers of orders, store products of different sizes and shapes, and facilitate efficient picking and packaging. A rack system suitable for high-density storage and fast delivery of bulk goods is esstential.

Carton Flow Racking system is a poplar solution for e-commerce warehouse,used in amazon,walmart,ebay warehouse. Carton Flow Racking allows products through rollers or wheels that cartons to glide from the back (loading) aisle to the front (picking) aisle. It is a good way to increase the turnover rate of the e-commerce warehouse.

Refrigerator Warehouse(coolroom racking)

Refrigerator Warehouse,as known as cold storage warehouse, or freezer warehouse, maintains specific temperatures using a refrigeration system. Different to other warehouse, the coolroom racking system designed to distribute the heat evenly in the room and prevent heat loss. General,the refrigerator warehouse used to preserve the freshness of various food,pharmaceuticals and medical Products,chemicals,etc. The racking system needs adapt to quick cooling and FIFO. Drive-in Racking is the best choice.

Dry Storage Warehouse

Dry warehousing is a type of commercial warehousing with storing consumer & packaged food inventory stored at room temperature.The chenllege of dry warehouse is keeping the goods dry (such as electronic goods) and away from extreme temperatures and on time and fast delivery for final sale. This kind of warehouse generally needs a combination of several types of pallet rack system. It is recommended to obtain a complete storage solution from a professional pallet racking manufacturer.

Optimize Space Utilization

Maximizing vertical space is crucial for efficient warehouse design:

  • Measure clear height to ceiling joists or sprinkler systems
  • Consider high-bay racking for facilities with tall ceilings
  • Ensure your material handling equipment can safely reach top levels
  • Implement narrow aisle racking to increase storage density

Plan Efficient Traffic Flow

A well-designed layout facilitates smooth movement of goods and personnel:

  • Create a logical flow from receiving to shipping areas
  • Design wide enough aisles for your material handling equipment
  • Implement cross-aisle picking for improved efficiency
  • Consider implementing a one-way traffic system to reduce congestion

Integrate Technology and Automation

Modern warehouses benefit greatly from technological integration:

  • Implement warehouse management system (WMS) for inventory control
  • Consider using an automatic storage and retrieval system (AS/RS) for high-density storage
  • Use bar codes or RFID systems for accurate tracking
  • Explore robotic picking systems to improve efficiency

Prioritize Safety and Compliance

Safety should be paramount in your warehouse layout design:

  • Ensure proper lighting throughout the facility
  • Install safety barriers and column protectors
  • Implement clear signage and floor markings
  • Design ergonomic workstations to reduce employee strain
  • Comply with local fire safety regulations and maintain clear access to exits

Create Dedicated Zones

Organize your warehouse into functional zones:

  • Receiving area for incoming goods
  • Staging area for order preparation
  • Packing and shipping zone
  • Returns processing area
  • Value-added services section (if applicable)

Implement Efficient Picking Strategies

Design your layout to support efficient order picking:

  • Place fast-moving items in easily accessible locations
  • Consider implementing zone picking for multi-line orders
  • Use batch picking for similar orders to reduce travel time
  • Explore pick-to-light or voice-picking systems for increased accuracy

Plan for Flexibility and Growth

Future-proof your warehouse layout:

  • Use modular racking systems that can be easily reconfigured
  • Leave room for potential expansion or addition of new technologies
  • Consider multi-purpose areas that can adapt to changing needs

Utilize Software for Layout Planning

Leverage warehouse design software to:

  • Create 3D models of your layout
  • Test different configurations virtually
  • Analyze traffic flow and identify potential bottlenecks
  • Calculate storage capacity and optimize space utilization


Contact Heda Shelves to simplify your custom warehouse rack and optimize storage with the best pallet racking system for your needs. We provide full-service support, design and engineering from our expert team with 20+ year experience. Discovery the best warehouse storage solution with heda. Call Us Today!

Abby Xu
Abby Xu

Welcome to my blog! I'm Abby Xu, with over 20 years of experience in warehouse and supermarket shelving sales. I've dedicated my career to optimizing storage and enhancing retail displays. Join me for insights and tips to streamline your operations and boost sales.

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