Drive In Racks vs Shuttle Pallet Racking: Which Is Best for You?

An effective warehouse is like an IKEA apartment plan. The goal is to maximize storage space without impacting functionality. Two of the biggest space wasters are unused vertical storage and excess aisle space. 

If you store large volumes of individual SKUs and want to minimize wasted space, Drive in racks and shuttle pallet racking might be the solutions for you. However, these similar racking styles have some key differences to consider before you invest. Read on to learn the advantages and disadvantages of drive in and shuttle racking, as well as which option is best for your facility.

Drive In Racking

Drive in racks are a pallet rack organization method that focuses on storage density over selectivity. In this method, racks form a dense matrix of pallets, often half a dozen deep. A forklift fills the racks by driving into the matrix and loading pallets back to front. Unloading typically follows the reverse pattern.

Advantages

This style of rack organization offers several benefits.

• Improved storage density. Drive in racking increases storage space by removing unnecessary aisles. Since the forklift drives into the racking directly, there is no need for aisles between the individual pallet racks that make up the rack matrix.
• LIFO or FIFO. In the traditional arrangement, the rack matrix stands against a wall, allowing access from one direction. This format works excellently for a last-in-first-out inventory management style. However, by placing a forklift-accessible aisle behind the racking, drive in racking becomes drive through racking. This lends itself well to first-in-first-out inventory management as the racks load from one side and pick from the other.
• Reliability. This racking style features no moving parts. Consequently, it does not break down and is failure-resistant, making it a highly dependable racking style.
• Cost-effective. Drive in racking uses standard racking components, requires no electricity, and minimum maintenance. Furthermore, it maximizes the storage footprint of your facility. As a result, it is a highly cost-effective storage solution.

Disadvantages

Depending on your storage needs, drive in and drive through racking have a couple potential downsides.

• Reduced selectivity. The density of the drive in rack design means some pallets in the middle are inaccessible until other pallets are removed. This reduces the selectivity of this racking style and makes it best suited for use with a single SKU per column.
• Increased damage potential. Since forklift operators must drive their trucks into the racking, there is an increased risk of collision. A forklift colliding with racking can severely damage the rack’s structural integrity and increase the risk of a collapse.

Shuttle Pallet Racking

Shuttle pallet racking (or radio shuttle pallet racking) is a modern variation on the traditional drive in racking model. It uses the same high-density racking matrix. However, instead of the forklift driving into the racking, it uses radio-controlled shuttles that run on tracks beneath each tier. When directed, the shuttles select the nearest pallet and move it to the front of the rack. One shuttle can attend to multiple levels since they can move between tiers via forklift.

Advantages

Shuttle pallet racking has many of the same benefits as drive in racking, with a few unique advantages.

• Increased productivity. When picking multiple pallets, the forklift operator can pick the first and then send the shuttle back for the second while the driver delivers the first. This eliminates both the need to drive into the racking as well as time spent waiting on the shuttle, allowing operators to reclaim more productive hours.
• Reduced racking damage. Since fork trucks no longer have to drive into the racking, the chance of collision is dramatically reduced. This creates a safer working environment and reduces expensive racking repairs.
• LIFO or FIFO. Radio shuttle pallet racking can be configured for last-in-first-out or first-in-first-out inventory management. The bi-directional shuttles allow operators to select which side of the racking to use for loading and which to use for picking.
• Cold storage safe. Some shuttle models are suitable for work in cold or even sub-freezing temperatures, making them excellent choices for food storage industries.
• Increased storage efficiency. Since shuttle pallet racking doesn't require the interior space to fit a forklift, tiers can be closer together. This allows you to use the space more efficiently with fewer dead spots.

Disadvantages

Like all other types of racking, radio shuttle pallet racking has a few things to be aware of before investing.

• Increased maintenance. The shuttle introduces an additional moving part. This machine requires maintenance like any other and can break down. Consequently, it’s advisable to have several shuttles in your racking system so that your racks don’t become inaccessible if a shuttle breaks down.
• Increased cost. The shuttle and track are additional costs in the initial investment of this system. As such, shuttle pallet racking is more expensive than drive in racking. However, busy warehouses are likely to recoup that initial expenditure in increased productivity.

Combined Pallet Racking Solutions

No single racking style is a one-size-fits-all solution. In fact, most facilities benefit from a combination of various racking styles and storage solutions. If you're looking to optimize your warehouse, expert analysis is the answer. Our solutions team can help you choose the most efficient and affordable racking solutions for your operation and have them professionally installed. So, if you're ready to optimize, let us help. Contact us online or visit one of our locations throughout Georgia and Florida to learn more about warehouse storage solutions and optimization.

Florida
Jacksonville
Lakeland
Ocala
Orlando
Tampa
Winter Haven

Georgia
Albany
Macon
Columbus
Valdosta

Further Reading
Optimize Your Warehouse Efficiency: Dynamic Storage vs. Static Storage Solutions Explained
What Is an Automated Storage and Retrieval System (ASRS)?
Is Your Pallet Racking OSHA Compliant