What is Double Deep Racking?
Double Deep Racking is a high-density pallet storage system designed to increase warehouse capacity by storing pallets two rows deep instead of a single row. Compared to traditional selective racking, it can improve storage density by approximately 40–60%.
To access the rear pallet, this system requires a specialised forklift with an extended reach mechanism, such as a telescopic or pantograph attachment. Because the front pallet must be moved to access the rear pallet, the system operates on a Last-In, First-Out (LIFO) inventory principle, making it a perfect fit for specific operational needs.
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How Does Double Deep Racking Work?
Double deep racking operates by storing two pallets in depth within the same lane, rather than allowing direct access to every pallet from the aisle like standard selective systems. Within each bay, pallets are arranged in a front-to-back configuration to optimise storage space.
The basic operating process includes:
- One pallet is placed in the front position
- A second pallet is stored directly behind it
- When the rear pallet is required, the front pallet must be removed first
The system is typically operated using reach trucks or specialised forklifts equipped with extended reach mechanisms such as pantograph or telescopic fork systems. When designed properly, double deep racking gives businesses a practical way to increase pallet capacity without significantly expanding the warehouse footprint.
Key Benefits of Double Deep Warehouse Racking
Implementing a Vinatech Double Deep Racking system is a strategic decision that delivers significant improvements in capacity and cost-efficiency.
- Dramatically Increase Storage Density: The primary benefit is a substantial increase in storage capacity. By eliminating nearly half of your aisles, you can achieve a warehouse fill capacity of up to 80-85%. This means you can store significantly more product in the same footprint, maximising the value of your existing facility.
- Cost-Effective Capacity Growth: Double Deep Racking offers a lower cost-per-pallet position than standard selective racking. It allows you to expand your storage capabilities without the major capital expenditure of building expansion or moving to a new site, also leading to reduced costs for lighting and cooling in larger facilities.
- Ideal for High-Volume SKUs: This system excels in environments where you store multiple pallets of the same SKU. It is perfectly suited for fast-moving consumer goods, seasonal products, or any inventory where the front pallet of a given product is typically depleted before access to the rear pallet is required.
Warehouse Applications for Double Deep Racking
Double deep racking is particularly suitable for warehouses that need higher pallet density without moving to more complex automation systems.
- Cold storage and food distribution: Cold storage is one of the most suitable applications for double deep warehouse racking. When product lines are stored in large batches and pallet uniformity is high, Double Deep Racking allows operators to increase storage capacity while limiting the need to expand refrigerated space.
- Manufacturing and FMCG: Manufacturing businesses and FMCG warehouses often store repeated pallet loads of raw materials, packaging, or finished goods. In these environments, the priority is to position more stock close to production or dispatch areas while still maintaining safe forklift access and an efficient replenishment flow.
- Retail and wholesale distribution: Retail distribution centres and wholesale operations often store high-volume product lines, promotional stock, and seasonal inventory, which do not necessarily require a highly selective layout with excessive aisle space.
- 3PL and contract logistics: For 3PL providers, suitability depends on the customer profile. Multi-client warehouses with many small-volume SKUs and high stock variation may still be better suited to more selective storage systems. However, double deep pallet racking creates more pallet positions within the same footprint while still offering a practical level of accessibility.
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Vinatech’s Double-deep pallet racking system
Our Double Deep Racking is designed and engineered to be fully compliant with the AS 4084-2023 Australian Standard for Steel Storage Racking. The system is built for durability and stability, featuring:
- High-strength steel uprights and heavy-duty beams with a capacity of up to
3000 kg per level. - Robust frame ties that securely connect the front and rear racks, ensuring structural integrity.
- A maximum height of up to 10 metres to make the most of your vertical space.
Vinatech Australia: Industrial Warehouse Racking – Warehouse Shelving Solutions
- Website: https://vinatech.com.au/
- Phone number: 0406 916 355
- Email: info@vinatech.com.au
- Address: 34 Paramount Bvd, Cranbourne West VIC 3977, Australia
FAQs about Double Deep Racking
Double deep racking is a high-density warehouse storage system that stores pallets two positions deep instead of one, increasing storage capacity while reducing aisle space.
Double deep racking works by placing pallets in two rows deep within the rack. Specialised reach trucks are used to access both front and rear pallet positions efficiently.
The main benefits include increased storage density, reduced aisle space, improved warehouse space utilisation, and lower cost compared to fully automated systems.
Selective racking provides direct access to every pallet, while double deep racking stores pallets two deep, increasing storage density but reducing accessibility.
It is best suited for high-volume, low-SKU goods with consistent pallet sizes, such as packaged products, bulk items, and non-perishable inventory.
