Distribution Centre Storage Solutions

The most common storage system in distribution centres is selective pallet racking, which typically accounts for around 80–90% of what you’ll see in these environments. These systems are used to store palletised goods and can be installed in ambient warehouse conditions, cold rooms, or freezer rooms.

Freezer environments present a particular challenge. At temperatures as low as minus 20 degrees, racking must be significantly more robust, and any maintenance or repairs become extremely difficult. Because of this, the design of freezer racking is critical, with the goal always being to minimise the need for repairs and ongoing intervention wherever possible.

Choosing between selective racking, double-deep, or higher-density systems like drive-in racking is very much dependent on the type of business and the products being stored. For example, in supermarket-style distribution centres, drive-in racking is common in freezer or cool rooms where there are high volumes of the same product. In these expensive temperature-controlled environments, dense storage makes sense to maximise capacity and reduce operating costs.

In other types of distribution centres, such as those servicing construction, infrastructure, or trade customers, storage requirements can include a wide mix of systems. These may involve selective pallet racking, mezzanine floors, cantilever racking, and dedicated picking and packing areas. There is no one-size-fits-all approach; every solution is specific to the business, the products, and the customers it serves.

Most distribution centres are built around three core zones: incoming goods, picking and packing, and outgoing dispatch. Within those zones, there may be different room conditions such as ambient storage, cold rooms, or freezer rooms. While the zoning itself is relatively simple, the sheer scale of distribution operations can make these environments highly complex.

Distribution centre layouts are largely dictated by the building shape and the forklift equipment being used. Forklift selection has a major impact on aisle widths, lifting heights, load capacities, safety requirements, and rack protection needs.

In many cases, forklift decisions have already been made before storage design begins, sometimes based on long-standing or legacy equipment. In those situations, racking systems must be designed to work within the constraints of the existing forklifts. Where businesses are more flexible, newer forklift designs can allow for much denser racking configurations and significantly better use of available floor space.

The biggest challenge in distribution centres is speed. These environments are highly time- and schedule-driven. Goods need to be received, stored, picked, and dispatched extremely quickly. The pressure to meet tight deadlines often leads to increased risk of damage within the warehouse.

In many cases, the level of rack damage seen in distribution centres is directly linked to the speed at which operations are expected to run. Good design, appropriate rack protection, and anticipating high-impact areas all play a critical role in reducing damage and avoiding costly repairs year after year.

Because distribution centres handle such a wide variety of products, they often require a broad mix of storage systems, including:

• Selective pallet racking
• Double-deep and drive-in racking
• Cantilever racking for long or bulky items
• A-frame shelving for extrusions
• Cable racking for coils and reels
• Drum and liquid storage systems

In many cases, a single distribution centre will use multiple systems across different zones.

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