High-density storage compacts the maximum number of pallets into a reduced space by removing circulation aisles: drive-in racking, push-back, gravity pallet flow or semi-automatic pallet shuttle. These systems suit large volumes of homogeneous pallets and save up to 80% floor space compared with standard pallet racking; they are widely used in cold rooms.
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| Drive-in racking | Storage lanes the forklift drives into to place pallets on continuous rails: maximum density, LIFO or relative FIFO management, ideal in cold rooms. |
|---|---|
| Push-back racking | Up to 5 pallets deep per level on roller carts: each loaded pallet pushes back the previous ones, the last one loaded stays available at the front (LIFO), maintenance-free. |
| Pallet flow racking | Lanes of slightly inclined roller beds: the pallet rolls by gravity towards the lane exit (FIFO), perfect for stock rotation and use-by dates. |
| Pallet shuttle | Semi-automatic shuttle driven by remote control that carries the pallet along the rails and positions it precisely: high throughput, LIFO or relative FIFO. |
Which high-density storage system to choose?
Four questions guide the choice of system:
- Stock rotation: strict FIFO (use-by dates, traceability) → pallet flow; LIFO acceptable → drive-in or push-back
- Pallets per SKU: these systems store one SKU per lane or per level, they require homogeneous volumes
- Loading rate: beyond a few dozen movements per day and per lane, the pallet shuttle pays back its extra cost
- Environment: in cold rooms every square meter counts — drive-in and shuttle are the most common there
Drive-in, push-back, pallet flow or shuttle: comparison
| System | Principle | Rotation | Typical use |
|---|---|---|---|
| Drive-in | The forklift enters the lane | LIFO / relative FIFO | Large homogeneous volumes, cold rooms |
| Push-back | Pallets pushed on roller carts, up to 5 deep | LIFO | Medium rotation, products available at the front |
| Pallet flow | Gravity descent on rollers | FIFO | Date-sensitive products, order preparation |
| Pallet shuttle | Remote-controlled semi-automatic shuttle | LIFO / relative FIFO | Very large volumes, high throughput |
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