This document discusses various pallet storage and material handling systems. It describes block stacking, stacking frames, single-deep pallet racks, double-deep pallet racks, drive-in racks, pallet flow racks, push back racks, mobile pallet racks, walk behind pallet jacks, counterbalanced lift trucks, straddle trucks, side loaders, turret trucks, and automated storage and retrieval systems. The appropriate application of each system depends on factors like pallet quantities, stackability, and retrieval methods.
2. Pallet Storage
Block stacking:
Stored on the floor
Pallets are stacked on top of each other
Stack ability and stack height are dependent on the following
factors:
Weight
General stability
SOPs/Safety/OSHA acceptable safety limits
Floor lead restrictions
Physical height availability
Crush limits
3. Pallet Storage
Block stacking:
Use when retrieving product based on LIFO (Last In
First Out)
Not optimal for FIFO (First In First Out)
Best for large number of pallets for same SKU, low cost,
no racking
5. Pallet Storage
Stacking Frames:
Portable and collapsible frames
Build as needed
Steel uprights with steel decking
Easy to collapse and storage is compact
Use for loads/pallets that are unsafe to
stack on top of each other
6. Pallet Storage
Single-Deep Pallet Rack
Permanent racking only one pallet deep
Can store multiple SKUs in same column and
row
Best to be used with loads that are not stackable
and SKUs with only a few pallets of product
8. Pallet Storage
Double-deep pallet rack
Permanent racking two pallets deep
Use with SKUs with five pallets or more of
product AND retrievals that are in multiple of
two pallets
Use with high volume SKUs
Can save significant space over single-deep
pallet racks
10. Pallet Storage
Drive-In Rack:
Able to drive into the rack
Racks are up to ten pallets deep
Pallets are stored on rails instead of decking
Use with SKU quantities of five pallets or greater
Best when have SKU totaling 20 pallets or more
Downside, much slower production due to
confined space
12. Pallet Storage
Pallet Flow Rack
Similar to Drive-In Rack but has rollers on the
rails
Pallets are removed FIFO from the side opposite
from which it was loaded
As pallets are removed the remaining pallets roll
forward
Use with SKUs totaling ten pallets or more
14. Pallet Storage
Push Back Rack
Similar to pallet flow rack
Pallets are removed LIFO from the same side
they are loaded
Load new pallet by pushing existing pallets back
Remove a pallet and the remaining pallets flow
forward
16. Pallet Storage
Mobile Pallet Rack
Series of single deep racks abutted next to
each other with no aisle in between
Aisles are creating by pushing or cranking
rows apart
Upside: considerable space savings
Downside: very slow production
18. Material Handling Equipment
Walk Behind Pallet Jack
May be manually operated or motorized
Operate from a walking position
Motorized versions may be capable of reaching low
heights
Best for short distance move
19. Material Handling Equipment
Counterbalanced Lift Truck
Lift truck with the weight on the back end to counter the
weight of the load on the forks on the front end
20. Material Handling Equipment
Straddle Truck:
Instead of using counterbalance to provide stability, this
truck uses outriggers to straddle the pallet.
21. Material Handling Equipment
Side Loader:
Loads from the side. Forks are located on the
side not the front.
Allows the operator to travel down the aisle
without having to turn the truck to retrieve a
pallet
Downside: Can only reach one side of the aisle
from a given direction of travel.
23. Material Handling Equipment
Turret Truck
Forks swing on the mast to either side
Allows for more narrow aisle spacing
24. Material Handling Equipment
Automated Storage Retrieval (ASR)
Generally computer controlled
Retrieval truck follows a computer controlled fixed path
Storage locations consist of a matrix of fixed locations