Let’s imagine for a moment that you, as a warehouse owner, have a difficult choice to make. Your warehouse facility is a mess and your items are unorganized. You need an entirely new system to ensure the safety of your employees as well as the viability of the merchandise you are storing. There are two options you can select from: a racking system or stacking them on top of each other (block stacking). You look over your facility and discover that either option would work as your warehouse is large and has a lot of space, but which choice is best? Should you just stack everything, or would it be better to use a pallet rack system with a forklift to store your items?

Regardless of the industry, when it comes to selecting an appropriate warehouse storage solution, business owners have difficulty deciding on whether money should be spent on industrial storage systems or if their items should be stacked on the floor via block stacking. If you aren’t sure, don’t worry. Both options are okay depending on the circumstances. Just be aware that there are advantages and disadvantages for each storage solution depending on the material-handling situation you have.

This blog discusses comparisons between used pallet rack systems and block stacking. To learn more about the important decisions facing the two different storage options, read on.

Block Stacking

One of the cheapest, simplest storage methods is block stacking which means stacking and storing the pallets of loads on top of each other. You don’t need to purchase any type of storage equipment for this method. All you need to do is store your items in pallets until the maximum storage height is achieved. This is determined by factors such as the warehouse ceiling weight and height and basic load features such as strength, weight, and volume.

Block Stacking Advantages:

  • Low-cost
  • Flexibility

Block Stacking Disadvantages:

  • Low product retrieval and accessibility
  • Low storage density
  • Small space utilization

Pallet Racks

Pallet racking is more commonly used to store and handle materials. This storage system includes stacking loads in racks that are composed of stainless steel. Other elements included in the system are uprights, bays, and beams. Pallet racking isn’t very expensive and is much more beneficial in the long term. It is designed to increase productivity and safety, reduce employee downtime, and maximize workspace.

Advantages of Pallet Racks:

  • Optimized space utilization
  • Improved organization of space
  • Minimal risk of product damage
  • Reduced labor and operating expenses
  • Increased productivity
  • Makes stored products easier to access
  • A more effective solution to store items
  • Increased safety and storage space

Which One is Better?

The following is some information about both storage types.

Block stacking doesn’t require pallet rack systems and is inexpensive. It works well for products that demand first in first out (FIFO) or have long shelf lives. One disadvantage is that you will need lots of space to utilize this storage method, however, all you have to do is place the pallets on the floor and stack the pallets.

On the other hand, pallet racks or shelves are a better solution and only require an initial investment. Plenty of materials can be stored in compact, small spaces if the shelving is well-organized. The only parts that are required are whatever needs to be loaded onto containers and can be positioned in the front lines. Any parts not needed in the immediate future can be stored in the back. This is dependent on the quantity and weight of the parts as well as the load-bearing capacity of the pallets or racks.

Pallet racking systems may require material handling equipment such as forklifts to remove or lift bulky materials from cramped spaces without damaging other items in the process. If pallet racking is installed properly, materials and workers will be much safer. Lost production time is also saved as parts or materials can be arranged in an orderly manner. Operational costs are reduced as well as those that incur due to product damage or falls. Regular audits and inspections must be carried out to ensure that the order or the parts are not damaged. Actual quantities of available parts can only be matched to required parts if inspections are conducted. Audits help check to see if any parts are damaged. Inspections may be tedious, but they are effective in the long run.

Your decision regarding block stacking versus pallet racking would depend on the type of components or materials that are being stored along with many other factors. Each option has its own pros and cons. If you need an appropriate storage solution for your warehouse facility, contact us.