Selecting the right racks is the key to successfully operating a warehouse in Japan.
One of the most important challenges is how to make the most of limited warehouse space while improving both storage efficiency and shipping capacity.
In this column, we will discuss the essential points to consider when choosing storage racks, including steel racks and pallet racks.

Designing for Maximum Storage Efficiency and Shipping Capacity

In warehouse design, it is crucial to optimize the use of limited space to enhance storage efficiency while also ensuring smooth shipping operations.
By balancing these two factors, you can achieve efficient and safe warehouse operations.

Reference Standards for Aisle Widths

The required aisle width varies depending on the type of forklift and the type of racks used.
Below are the standard reference widths for different setups.

For Steel Racks:

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

For Pallet Racks:

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

Selecting Equipment with Forklift Traffic in Mind

Types of Forklifts and Their Movement Paths

• Counterbalance Forklifts: Powerful and capable but require wider aisles.
• Reach Forklifts: Operable in narrow aisles, making them ideal for high-density storage.

Key Considerations for Traffic Flow Design

• Straight-Line Paths: Enhancing work efficiency through direct, uninterrupted routes.
• Minimizing Cross Points: Reducing intersections to lower the risk of collisions.
• Emergency Escape Routes: Ensuring safe evacuation paths in case of emergencies.

Real-World Case Studies

Case Study 1: Maximizing Storage Efficiency with Medium-Duty Racks

• Challenge:
  The client wanted to maximize storage capacity while maintaining efficient inbound and outbound operations.
• Solution:
  We designed a rack layout with a 950mm aisle width based on shipping frequency and the type of order-picking vehicles used.
• Result:
  Achieved high storage efficiency while ensuring smooth inbound and outbound operations.

Case Study 2: Optimizing Storage and Shipping Efficiency with Pallet Racks

• Challenge:
  The client wanted a pallet rack layout optimized for reach forklifts to achieve both high storage density and efficient inventory movement.
• Solution:
  We designed a 2,800mm aisle width layout, considering forklift movement paths and warehouse flow.
• Result:
  Successfully achieved high shipping and storage efficiency while maintaining operational safety.

Conclusion

By understanding the relationship between aisle width and rack selection while considering forklift movement paths, you can significantly enhance warehouse efficiency and safety.
When choosing steel or pallet racks, be sure to take aisle width and forklift type into account to achieve the optimal warehouse design.