Selecting the right type of racking system is a key factor in successfully operating a warehouse in Japan.
One of the biggest challenges is how to maximize limited warehouse space while improving both storage efficiency and shipping capacity.

This article highlights the essential considerations when choosing storage racks—whether steel racks or pallet racks—to ensure safe and efficient warehouse operations.

Designing for Maximum Efficiency

In warehouse planning, two priorities must be balanced:

1. Maximizing storage capacity within limited space.
2. Maintaining smooth inbound and outbound operations for fast shipping.

When these are optimized together, the result is a warehouse that is both efficient and safe.

Reference Standards for Aisle Widths

The required aisle width depends on the type of forklift and the rack system in use. Below are general guidelines:

For Steel Racks

• Light to Medium-Duty Racks: 900–1,000 mm
• Medium-Duty Racks: 1,200 mm
• Operations Without Order Picking Vehicles: 800 mm

For Pallet Racks

• With Counterbalance Forklifts: 3,700 mm
• With Reach Forklifts: 2,800 mm

Selecting Equipment with Forklift Traffic in Mind

Forklift Types and Movement Characteristics

• Counterbalance Forklifts: Strong lifting power but require wider aisles.
• Reach Forklifts: Maneuverable in narrow aisles, ideal for high-density storage.

Key Considerations for Traffic Flow

• Straight-Line Routes: Direct paths improve efficiency and speed.
• Minimize Intersections: Fewer crossing points reduce the risk of collisions.
• Emergency Escape Routes: Always secure evacuation paths for safety.

Real-World Case Studies

Case 1: Maximizing Storage with Medium-Duty Racks

• Challenge: The client needed to expand storage capacity without slowing down order picking.
• Solution: We designed a layout with 950 mm aisles, based on picking frequency and vehicle use.
• Result: Achieved high storage efficiency while keeping inbound and outbound flows smooth.

Case 2: Optimizing Pallet Racks for Reach Forklifts

• Challenge: The client wanted both high-density storage and efficient inventory handling.
• Solution: Designed a pallet rack layout with 2,800 mm aisles, tailored to reach forklift operations.
• Result: Delivered high storage and shipping efficiency while maintaining safe traffic flow.

Conclusion

By carefully considering aisle widths, rack type, and forklift movement paths, you can significantly improve warehouse efficiency and safety.

When selecting steel racks or pallet racks, always evaluate:
✔️ Aisle width requirements
✔️ Forklift type and traffic flow
✔️ Balance between storage and operational efficiency

With the right design, you can maximize space, streamline logistics, and create a safer work environment.