Why Your Choice of a Double Deep Pallet Racking System Manufacturer Matters
In the quest for warehouse efficiency, a double deep pallet racking system stands out as a smart upgrade from selective racking, offering a significant boost in storage density. However, the success of this system hinges on more than just the concept; it depends on the expertise and quality of your supplier. Choosing the right double deep pallet racking system manufacturer is the most critical decision you will make. Bari Engineering isn’t just a supplier; we are your engineering partner, dedicated to designing, manufacturing, and installing systems that deliver unparalleled safety, durability, and return on investment.
What is a Double Deep Pallet Racking System?
A double deep pallet racking system is a high-density storage solution that stores pallets two-deep in each row, as opposed to the single-deep configuration of selective racking. This design effectively reduces the number of aisles in your warehouse by half, dramatically increasing storage capacity without expanding your building’s footprint.
The system relies on a specialized forklift—typically a reach truck with an extended reach mechanism—to access the second pallet position. The first pallet is stored directly on the floor-level rail, while the second is stored behind it on an elevated rail. This creates a compact, efficient storage lane that is ideal for large-volume SKUs.
The Engineering Behind a Reliable System
The effectiveness of a double deep pallet racking system is rooted in precision engineering. Unlike standard racking, it requires specific design considerations to ensure stability and accessibility.
The Importance of Upright Frame Design
The upright frames must be engineered to handle the increased load and potential torsional stress. As a professional double deep pallet racking system manufacturer, Bari Engineering uses heavy-duty, high-strength steel and often employs braced frames to ensure the structure remains rigid and secure, even when fully loaded.
Specialized Load Beams and Wire Decking
The load beams for the second position must have a specific profile to allow the forks of a reach truck to slide underneath effortlessly. Additionally, wire mesh decking is often recommended for the front pallet position. This decking provides a stable surface for the pallet while allowing the forklift forks to pass through to retrieve the rear pallet.
Precise Lane Depth and Alignment
Accuracy is non-negotiable. The lane depth must be calculated precisely to accommodate two standard pallets with minimal clearance. Even a slight misalignment during installation can render the rear positions inaccessible. This is where the installation expertise of a seasoned manufacturer becomes invaluable.
The Bari Engineering Advantage as Your Manufacturer
Partnering with Bari Engineering means more than just purchasing components. It means gaining a partner committed to your operational success from concept to completion.
Custom-Engineered Solutions for Your Needs
We reject the one-size-fits-all approach. Our process begins with a detailed analysis of your warehouse, including floor conditions, ceiling height, inventory profiles, and equipment. We then use advanced modeling software to design a double deep pallet racking system that maximizes your space and complies with all relevant safety standards.
In-House Manufacturing and Quality Control
As a double deep pallet racking system manufacturer with control over our production, we guarantee quality. We fabricate key components to exacting standards, using superior materials and rigorous quality checks. This control ensures every beam, frame, and connector meets our high specifications for strength and durability.
Seamless Project Management and Installation
Our team of certified installers brings the design to life with precision and efficiency. We manage the entire project timeline to minimize disruption to your workflow. Proper installation is critical for the safety and functionality of a double-deep system, and we treat it with the importance it deserves.
Key Benefits of a Bari Engineering Double Deep System
Investing in a professionally engineered system delivers measurable advantages.
Optimized Storage Density
By doubling the storage depth, you can typically increase your pallet positions by 40-50% compared to selective racking. This is one of the most cost-effective ways to gain significant storage capacity.
Compatibility with Standard Equipment
While it requires a reach truck, you do not need highly specialized or automated equipment. This makes the double deep pallet racking system a accessible step into high-density storage for many operations.
Improved Space Utilization
The reduction in aisles translates directly into more space for storage. This efficient use of your warehouse cube can delay or eliminate the need for a costly facility expansion.
FAQ: Your Questions as a Double Deep Racking Manufacturer, Answered
Q1: What type of forklift is required for a double deep system?
A reach truck with a double-reach mechanism is essential. A standard counterbalanced forklift or a single-reach truck cannot access the second pallet position. The forklift must be specified correctly for the racking’s dimensions.
Q2: Is this system suitable for FIFO (First-In, First-Out) inventory?
Typically, no. A standard double deep pallet racking system operates on a LIFO (Last-In, First-Out) basis because the front pallet must be moved to access the rear one. It is ideal for storing identical products where stock rotation is not critical.
Q3: How does the cost compare to other high-density systems?
A double deep system is generally more affordable than fully automated systems (like ASRS) and even some mobile shelving solutions. It offers an excellent balance of increased density and manageable investment, especially when working with a manufacturer that controls costs.
Q4: What are the common mistakes to avoid when implementing this system?
The most common mistakes are: choosing an inexperienced installer, using incompatible forklifts, and poor SKU slotting. Storing different SKUs in the same lane is a major operational error. Partnering with an expert double deep pallet racking system manufacturer like Bari Engineering helps you avoid these pitfalls from the start.
Conclusion
Selecting the right double deep pallet racking system manufacturer is the foundational step to achieving your warehouse density goals. The system’s performance, safety, and longevity are directly tied to the quality of its design, components, and installation. Bari Engineering brings the engineering expertise, manufacturing quality, and project management skill required to deliver a system that not only meets but exceeds your expectations. If you are ready to double your storage capacity with confidence, contact Bari Engineering for a detailed consultation and custom quote. Let us engineer a solution that drives your productivity forward.
