Optimising space and productivity while reducing overhead is a significant goal for most warehouses. Sometimes, though, solutions like reorganising aisles or investing in a larger space aren’t an option.
This is where double-deep racking configurations can make a substantial impact. Double-deep racking is a type of pallet racking system where pallets are stored two rows deep, or one behind the other, on each side of an aisle. This effectively doubles the storage capacity per aisle when compared to conventional racking, which stores one pallet deep.
Utilising this system not only makes the most of warehouse space, but also benefits productivity. Keep reading to learn more about the benefits of double-deep racking, tips on how to implement it, how it can lead to significant cost savings, and most importantly, the types of trucks which work best with this system.
Why consider double-deep racking for your warehouse?
Depending on your industry and environment, double-deep racking is a potentially powerful configuration that can help you take full advantage of your available space.
Some key benefits include:
- Increased storage density: Up to 25–30% more pallets than conventional racking.
- Lower cost per pallet stored compared to drive-in or push-back systems.
- Retains accessibility better than deeper systems like block stacking or drive-in.
A deeper look into the cost savings of double-deep racking
The immediately apparent cost savings of double-deep racking is in its higher storage density. It allows for better use of expensive vertical and horizontal space. This means more product per square meter, or lower cost per pallet.
This space-saving solution means you may not need to move to a larger facility to accommodate growing inventory. Instead, you can delay moving or even undergoing an expansion project by simply reorganising your use of space.
And in the right environment, double-deep storage provides increased picking efficiency with fewer touches per pallet, reduced forklift travel time, and more streamlined workflows that lower overall labour costs.
Other less obvious cost benefits to consider include lower energy overheads. Fewer aisles means less lighting needed, and less floor space to climate control (especially important in a cold storage environment).
But most importantly, double-deep storage is generally a lower initial investment than deeper solutions, such as drive-in or automated shuttle systems (which use more steel). They are also simpler to install and configure, and usually don’t require as much building reinforcement.
That said, while there is usually an initial investment when shifting to double-deep storage, everything mentioned above naturally leads to a lower total cost of ownership.
Related: Ten tips to become a better forklift driver
How to build double-deep racking configurations
As with most warehouse configurations, building double-deep racking requires significant planning.
First, make sure that double-deep racking works for your environment. It’s usually most effective in low-SKU, high-volume storage, including distribution centres that manage seasonal stock, beverage and food production, cold storage, and bulk goods.
Next, evaluate your floor plan and load requirements. This includes measuring your available floor space and ceiling height. You will also need to determine pallet sizes, load weights, and the number of SKUs.
After measuring, you’ll need to install specialised racks. These are the standard uprights and beams, but configured for double depth, typically 2.4 metres deep. This also means reinforcing the increased weight load.
Finally, you will need to choose the right fork lifts. There are two types that can be used with double-deep racking. They include:
- Pantograph, or scissor reach mechanisms, or,
- Telescopic forks, which can extend to access the rear pallet without moving the truck.
Introducing TCM's SST/SRT stackers: telescopic forks for double-deep racking
TCM is proud to offer the unique and versatile SRT and SST. As part of our unique stand-in and sit-on stacker truck range, these trucks come with telescopic forks engineered with:
- Precision-speed regulation: extend or retract in unison for confident, safe operation.
- A Low-profile for safe and easy lifting between the straddle legs at floor level. This is especially suited to handling bottom boarded pallets.
The trucks themselves boast small turning circles ideal for tight spaces, and a lead-acid battery option for easy charging to suit all applications. On the SRT, low entry step height and excellent floor vibration damping reduce operator stress and fatigue.
Maintenance is streamlined with easy access to battery and motor compartments, with long service intervals to improve uptime.
If reducing warehousing costs is a priority, using the SRT or SST in conjunction with double-deep racking can trim 20% of the warehouse space needed for conventional single depth racking.
At TCM, we’re committed to providing our customers with innovative products that both advance productivity and improve TCO. Our SRT/SST trucks reflect this commitment with streamlined access to double-deep racking setups that will significantly improve your TCO.
Ready to learn more about the advantages of utilising our SRT/SST stacker trucks in your warehouse operations? Download your free brochure, or speak with one of our knowledgeable consultants today.
To learn more about the the SST or SRT trucks download our free brochure.
Additionally, you can reach out to a member of our specialist sales team.
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