At Erect-A-Rack, we know that optimising warehouse space isn’t just about cramming more pallets into a corner. It’s about smart design, safe systems, and future ready flexibility. So, let’s break down 7 proven ways pallet racking can help you maximise your warehouse space, boost productivity, and even cut costs along the way.
Warehouse space isn’t cheap and it’s only getting more expensive. Whether you’re managing a distribution centre or a small storage facility, every square metre counts. The good news? The right pallet racking system can help you unlock serious efficiencies in both storage capacity and operational flow often without needing to move or expand your premises.
1. Use Selective Pallet Racking for Maximum Accessibility
Best for: Warehouses with high product variety and fast picking requirements.
Selective pallet racking is the most common racking system and for good reason. It allows 100% access to every pallet, making it ideal for operations where stock rotation and order picking speed matter.
Efficiency benefits:
- Great for FIFO (first, in, first, out) inventory management.
- Reduces picking times by up to 30% with organised product placement.
- Easier to train staff and onboard new team members quickly.
While it doesn’t offer the highest density storage, its flexibility helps reduce time waste and forklift travel distances saving labour costs and improving order turnaround.
🔗 Learn more about Selective Pallet Racking
2. Install Double Deep Racking for Higher Density
Best for: Warehouses storing the same SKUs in multiple pallets.
Double deep racking stores pallets two rows deep, effectively increasing your storage density by up to 40% compared to selective systems. You’ll need a reach truck for access, but the trade, off is worthwhile for many medium to high turnover products.
Efficiency benefits:
- Reduces aisle space requirements.
- Ideal for medium rotation stock where LIFO (last, in, first, out) is acceptable.
- Up to 20% reduction in space costs per pallet stored.
This is a sweet spot between high, density and operational flexibility.
3. Go Vertical with Very Narrow Aisle (VNA) Racking
Best for: Warehouses with high ceilings and tight floor space.
If you’ve got height but limited footprint, VNA racking lets you take full advantage of it. With aisle widths reduced to around 1.6–2.0 metres, VNA systems can increase your storage capacity by up to 50% compared to standard selective racking.
Efficiency benefits:
- Reduces unused vertical space.
- High, density storage with advanced forklift guidance systems.
- Cuts travel distance for forklifts by using wire, guided aisles.
Yes, you’ll need specialised equipment (like a turret truck), but the increase in SKU storage per square metre often justifies the investment.
4. Use Drive In Racking for Bulk Storage
Best for: Cold storage, seasonal products, or high, volume SKUs.
Drive, in racking removes the need for multiple aisles altogether by allowing forklifts to drive directly into lanes of stacked pallets. This creates extremely high, density storage up to 75% more than selective racking.
Efficiency benefits:
- Great for reducing refrigeration space costs in cold storage.
- Ideal for LIFO operations with low SKU variety.
- Cuts down racking footprint while storing the same volume.
Used wisely, this system can reduce your per pallet storage cost by 30–40%.
🔗 Check out Drive In Pallet Racking
5. Implement Push Back Racking for Dynamic Inventory
Best for: Warehouses needing fast loading/unloading with high turnover.
Push back racking allows multiple pallets to be stored on inclined rails. When a pallet is removed, the next one slides forward. This system supports LIFO and is more flexible than Drive In racking.
Efficiency benefits:
- Speeds up pallet retrieval no need to enter the rack structure.
- Increases storage density by 25–30% compared to selective.
- Reduces forklift travel and handling time.
It’s a favourite for FMCG (Fast Moving Consumer Goods) industries or operations with busy loading docks.
6. Install Cantilever Racking for Long or Bulky Items
Best for: Timber, piping, steel lengths, or furniture storage.
Traditional racking systems won’t do for long, awkward loads. Cantilever racking offers open fronted storage and adjustable arms, making it easy to store items that don’t fit on standard pallets.
Efficiency benefits:
- Reduces product damage from improper stacking.
- Improves OH&S by enabling safer retrieval and handling.
- Frees up standard pallet racking for more appropriate items.
This system keeps bulky items organised and accessible, so your warehouse stays tidy and efficient.
🔗 Browse Cantilever Racking Options
7. Combine Mezzanine Floors with Racking Systems
Best for: Businesses running out of floor space but not ready to relocate.
When vertical space is underutilised, mezzanine floors can transform a single level into two or even three. Combine with selective or long, span shelving for picking operations, packing areas, or office space.
Efficiency benefits:
- Doubles usable space without increasing footprint.
- Avoids costly warehouse relocations or extensions.
- ROI within 12–18 months due to increased operational capacity.
It’s one of the most cost, effective ways to add value to your warehouse long, term.
🔗 See Mezzanine Floor Solutions
Final Thoughts: It’s About the Right System for Your Operation
The key to maximising warehouse space isn’t about squeezing more in it’s about using the right racking system for your specific needs. Each option above has its strengths depending on your:
- Product types and sizes
- Stock rotation needs
- Equipment and staffing
- Budget and growth goals
At Erect-A-Rack, we take the time to understand your operation and tailor a solution that not only improves your space efficiency but also enhances safety, productivity, and bottom line performance.
Want to discuss your warehouse layout or explore a tailored storage solution?
📞 Contact the team at Erect-A-Rack today or call 1300 788 916
Quick Recap: 7 Space Saving Racking Solutions
- ✅ Selective Racking – Fast access, best for high SKU variety
- ✅ Double Deep – Increased density for similar product lines
- ✅ VNA Racking – Uses height, perfect for tight floorplans
- ✅ Drive In Racking – Bulk storage with minimal aisle use
- ✅ Push Back Racking – High turnover, efficient handling
- ✅ Cantilever Racking – Long item storage, clean and safe
- ✅ Mezzanine Floors – Multi level storage without relocation
✅ Warehouse Racking Space Optimisation Checklist
📦 Step 1: Assess Your Inventory Profile
| Question | Yes | No |
| Do you store a large variety of SKUs? | ☐ | ☐ |
| Do you store identical pallets in bulk? | ☐ | ☐ |
| Are many of your items long or awkwardly shaped? | ☐ | ☐ |
| Do your products require FIFO inventory rotation? | ☐ | ☐ |
| Is high turnover speed more important than maximum density? | ☐ | ☐ |
🏗 Step 2: Measure Your Space
| Task | Notes |
| Measure floor area (m²) | ___________ |
| Measure clear ceiling height (metres) | ___________ |
| Identify under utilised vertical space | ☐ Yes ☐ No |
| Note forklift type and turning radius | ___________ |
🚚 Step 3: Evaluate Handling Requirements
| Question | Yes | No |
| Do you use reach trucks or turret trucks? | ☐ | ☐ |
| Is there enough room to turn in current aisle widths? | ☐ | ☐ |
| Do you need faster picking and order fulfilment? | ☐ | ☐ |
📈 Step 4: Match Needs to Racking Systems
| System | Best For | Check if Suitable |
| Selective Racking | High SKU access & FIFO | ☐ |
| Double Deep Racking | Moderate variety, higher density | ☐ |
| Very Narrow Aisle (VNA) | Limited floor space, tall ceilings | ☐ |
| Drive In Racking | Bulk pallets, low SKU variety | ☐ |
| Push Back Racking | Fast moving stock, LIFO | ☐ |
| Cantilever Racking | Long, irregular products | ☐ |
| Mezzanine Floors | Expanding up, not out | ☐ |
💡 Step 5: Estimate Benefits
| Metric | Current | With New System | Gain |
| Pallets stored per m² | ________ | ________ | +______% |
| Average picking time (mins) | ________ | ________ | ,______% |
| Labour hours per week | ________ | ________ | ,______ hrs |
| Estimated ROI period | – | ________ months | – |
📞 Step 6: Plan Your Next Move
- ☐ Contact Erect-A-Rack for a free consultation
- ☐ Request a warehouse layout review
- ☐ Ask about compliance and safety standards
- ☐ Get a custom quote with delivery and installation timelines
