Maximize the Use of Existing Warehouse Space Without Building New FacilitiesMay 22, 2008  A host of innovative warehouse solutions can enhance storage and distribution without breaking the budget
For those seeking to expand or improve warehouse storage and distribution without building costly new facilities, a host of innovative storage rack warehouse solutions can now help without breaking the budget. By increasing storage rack density or using wasted/overlooked space more efficiently, while keeping needed selectivity, warehouse managers can significantly add to the bottom line.
To maximize storage and selectivity, savvy warehouse managers are increasingly turning from traditional techniques like floor stacking and selective racks to advanced methods, such as the pushback pallet rack, which offers up to 90 percent more product storage than selective rack systems and up to 400 percent more selectivity than drive-in racks.
Unlike static, single-pallet deep selective racks, a dynamic pushback rack system allows storing pallets two to five deep while providing easy access to a variety of different SKUs. Pallets are stored behind each other in a series of nested carts and are loaded from the same side of the system, eliminating separate aisles for each function. Composed of a stable rack along with a series of inclined carts and rails, when one pallet is pulled, the one behind it rolls forward.
To quickly get forklift operators up to speed on the key differences between traditional static loads and the dynamic pushback system while avoiding forklift damage or pallet rack damage, proactive warehouse managers are training staff with the help of a free "Pushback System Safe Operating Procedures User Handbook," offered by Steel King Industries (www.steelking.com), of Stevens Point, Wisconsin, a leading manufacturer and provider of pushback and storage rack systems. The pushback safety handbook highlights best practice procedures, and illustrates them with easy-to-understand graphics.
By employing a pushback pallet rack system and principles covered in the safety manual, Meyer Material Handling, a national reseller and installer of material handling and storage systems, helped one wire-manufacturing customer implement a warehouse system that essentially doubled storage in about 60 percent less space, compared to a previous selective rack system, according to John Calkins, Vice President of Sales at Meyer Material Handling. "That lowered long-term overhead costs, while enabling expansion possibilities," says Calkins. "Many pushback systems can generate ROI in just over two years."
For maximum pallet rack use in a minimum footprint, along with inventory management capability, a warehouse pallet flow storage system can be the answer.
In a pallet flow storage system such as the SK3400 by Steel King, dynamic flow rails are inclined in a static rack structure, allowing loads placed on one end to move by gravity on rollers to the unloading end, with speed controllers acting as gentle brakes. As a load is removed, the loads behind it move forward automatically.
Once loaded, FIFO product rotation is automatic and the rack eliminates labor and fork truck operation to arrange loads. Forklifts are required only for the initial and final unloading. Compared to traditional selective pallet rack use, which requires multiple aisles, aisle space can be reduced by 75 percent and up to 100 percent more product can be stored.
"Combining rack types to better use vertical space can further improve storage density," adds Arlin Keck, Corporate Engineer for Steel King. "For instance, while sharing a common pick aisle, pallet flow can be used at the bottom of a rack structure with pushback at the top, adding an additional two to three pallet capacity per level."
As a solution to empty pallet storage problems, the Over-Dock Pallet Storage Rack by Steel King can not only help warehouse/logistics managers and shipping/receiving supervisors put more product in their warehouse without a bigger building, but also enhance safety, aesthetics and operational efficiency.
Like a kitchen cupboard in the kitchen, the Over-Dock Pallet Storage Rack keeps empty pallets safely out of the way until they're needed, when they're conveniently at hand in a specially designed over the loading dock storage rack that'll accommodate empty pallets, skids or returnable shipping containers.
With typically two shelves installed above an average 12-foot wide dock door, almost 100 sq. ft of additional floor storage space can be added above each dock door. That's floor space freed up for storing higher value items than empty pallets. The empty pallets are kept safe and secure above the dock door, right where they're needed, ready to handle incoming materials or ship outgoing goods.
With every square inch of warehouse storage space or factory floor space being used to its fullest, many companies are also looking to extend the use of existing square footage with free-standing elevated work platforms. Elevated work platforms or mezzanines are ideal for additional in-plant office space, archive/record storage, small parts storage, and picking and sorting operations.
An example of this platform is the Steel King ClereSpan Mezzanine. Available in variable first-level heights and spans up to 20 feet, this platform can be customized with a variety of floor surfaces, stairs, and gates. Flooring options range from standard roof decking and treated wood, to bar grating, metal and even concrete. The platform can be combined with other Steel King products to form a full turnkey system to match facility growth. Customize multi-level systems are also available.
For storage rack warehouse solutions customized to the application, Steel King racks can be custom designed or modified for seismic requirements, heavier loads or other needs.
For more info or a free copy of Steel King's "Pushback System Safe Operating Procedures User Handbook," contact Donald Heemstra at Steel King, 2700 Chamber St., Stevens Point, WI 54481; call 800-826-0203; email: dheemstra@steelking.com or visit the website www.steelking.com.
### | 
