Double Deep Racking is a type of pallet racking system that allows for increased storage density by storing pallets two deep within a single bay. This system effectively maximizes the available warehouse space, providing an efficient way to store large volumes of goods while minimizing aisle space. It’s a popular solution for warehouses with a relatively low product variety and moderate turnover rates.

How Double Deep Racking Works:

In a double deep racking system, each bay is designed to hold two pallets deep (one behind the other). This system requires specialized equipment, such as reach trucks or turret trucks, to retrieve pallets from the back of the rack. Pallets are placed in the system using a forklift, and the forklift must have the capability to reach deeper into the racks to handle the second pallet.

Key Features of Double Deep Racking:

Two Pallets Per Slot: Unlike traditional selective racking, where only one pallet fits per slot, double deep racks allow two pallets to be stored in a single slot — one in front of the other.

Increased Storage Density: By utilizing the depth of the warehouse, double deep racking increases the amount of storage in a given area without requiring more aisle space.

Requires Specialized Equipment: Double deep racks require forklifts or pallet jacks capable of extending deep into the racking system. Reach trucks or turret trucks are commonly used for this purpose, which are equipped with special forks that can reach to the second pallet.

LIFO (Last In, First Out): Double deep racking typically operates using the Last In, First Out (LIFO) inventory management system, meaning the most recently added pallet is the first one to be retrieved. This makes it ideal for warehouses with products that are not time-sensitive or perishable.

When to Use Double Deep Racking?

When the products have low SKU variety and high volume. This system is not ideal for businesses with a lot of product variety but works well for those storing large quantities of a few products.

For warehouses with moderate to low inventory turnover. Double deep racks are better suited for goods that don’t need to be accessed frequently.

When space optimization is a priority. If maximizing storage in a limited warehouse space is the goal, double deep racking is a practical solution.

Double deep racking systems are an excellent choice for warehouses aiming to maximize storage density while minimizing the need for excessive aisle space. They are best suited for industries that deal with high-volume, low-variability inventory, and where the use of specialized equipment (such as reach trucks) is not a significant barrier. By increasing storage capacity, improving space utilization, and reducing costs, double deep racking can be a valuable asset for many warehouses looking to optimize their storage solutions.