If your warehouse isn’t running as smoothly as it should, the racking system might be part of the problem. It’s easy to overlook, but the way your pallets are stored can either support your team’s productivity or get in the way of it.

The trick is finding a racking setup that matches the way you work. And that’s not just about shelf space. It’s about access, flow, movement, and safety.

What Does Your Day-to-Day Actually Look Like?

This is where it starts. Don’t jump straight into rack types and layout sketches. Step back and think about how your warehouse functions every day.

Are pallets constantly coming in and out, or do some sit for weeks? Do you have hundreds of SKUs to manage or just a few? Does your team need to pick from pallets regularly, or is it mostly bulk storage?

The way your operation flows affects the type of racking that makes sense. If access speed is critical, you’ll want something very different from a setup designed for long-term bulk storage. The same goes for whether you follow a FIFO (first-in, first-out) or LIFO (last-in, first-out) approach.

This isn’t just about efficiency. It’s also about safety, forklift access, and making sure your team isn’t wasting time navigating around a poorly thought-out system.

Not All Pallets—and Products—Are the Same

Next up, your inventory. It’s not just “pallets”—there’s a lot of variation here that affects what kind of racking you’ll need.

Some key things to consider:

  • Are your pallets standardized in size and weight, or does it vary?
  • How heavy is your average load?
  • Do you deal with awkward shapes, fragile items, or materials that expire?

These details might sound minor, but they can completely change what kind of system will support your operation best. A warehouse storing oversized items, for example, will have very different needs than one focused on food products that rotate quickly.

Be Realistic About Your Space

Racking design always comes back to your available square footage—and just as importantly, your vertical space. If your ceiling height allows for it, going vertical is often the most cost-effective way to scale. But it’s not always straightforward. Columns, sprinkler systems, lighting, and HVAC can all get in the way of how high you can actually rack. And if you’re working with narrow aisles or tight turning space, that might rule out certain systems altogether.

Always measure carefully and account for the equipment you’re using. What works in a CAD drawing doesn’t always work once a forklift is involved.

The Main Types of Pallet Racking

There are a number of different pallet racking types to choose from. It’s important to know the different options available to you so you can make the right decision. Selective racking is what most people picture first. It gives you direct access to every pallet, which makes it ideal for operations with a wide range of SKUs and high product turnover. It’s simple, flexible, and easy to adjust as needs change. The tradeoff? You’ll need more aisle space, which reduces storage density.

For higher-density storage, drive-in or drive-through racking is often used. These systems let forklifts enter the rack lanes to load and unload, which allows for tighter stacking. They work well for storing large quantities of the same item, but they’re not great if you need to access lots of different products regularly.

If you’re somewhere in between, needing better space use without sacrificing too much access, push-back racking could be a good fit. These systems use nested carts that slide along rails, letting you store several pallets deep while still accessing the front pallet easily.

Then there’s pallet flow racking, where gravity helps move pallets forward as others are removed. This setup is great for first-in, first-out workflows and high-volume environments. It’s efficient, but more complex to install and maintain.

Lastly, cantilever racking is worth mentioning for anyone storing long or bulky items like lumber or pipes. It’s not for pallets, but it solves a problem that traditional racks can’t.

Safety and Workflow Go Hand in Hand

Choosing the right system isn’t just about storage—it’s about keeping your team safe and your workflow smooth. Improper racking setups can lead to damaged stock, slowed operations, and even serious accidents.

You’ll want to make sure whatever you install:

  • Matches the weight capacity of your loads

  • Leaves enough space for forklifts and pedestrian paths

  • Complies with fire codes and structural requirements

And just as important: maintain it. Racks can get knocked, bent, or weakened over time. Regular inspections aren’t optional; they’re essential.

Think Ahead

The perfect system today might not be perfect in a year. Maybe you’re expanding product lines. Maybe you’re adding a second shift. Maybe seasonal spikes are becoming more intense. Whatever the case, choose a setup that can scale or shift as your needs evolve.

That might mean going for a more modular design. Or simply leaving some space to reconfigure as operations grow. What you want to avoid is being boxed into a system that works now but limits you later.

So, Which One Fits?

There’s no universal answer to which racking system is “best.” The right choice depends entirely on your operation—your products, your space, your pace, and your plans.

If you’re storing a wide range of products and need quick access to all of them, a selective rack setup will probably serve you well. But if you’re storing bulk quantities of a single item and need to maximize space, a drive-in or push-back system might be more efficient.

The key is making sure the system works for you. It should support how your team moves, how your products flow, and how your business is growing.