What is Double Deep Racking?
Double deep racking is a high-density storage system that positions one pallet behind another, with access from the same aisle. Compared with selective racking, it reduces the number of aisles needed to serve pallet positions, leaving more floor space available for storage.
Vinatech describes potential storage density improvements of approximately 40-60% compared with conventional selective racking. Your actual increase will depend on the warehouse layout, aisle widths, pallet dimensions and usable storage height. Treat this range as an indication for planning, rather than a guaranteed result.
Accessing the rear position requires a suitable forklift or reach truck with an extended reach mechanism, such as a telescopic or pantograph system. A pantograph uses an extending linkage to move the forks beyond their normal reach.
Because the front pallet blocks access to the rear pallet, each pair generally operates on a Last-In, First-Out (LIFO) basis: the pallet loaded last is retrieved first. This arrangement suits stock that does not require strict first-in, first-out retrieval within each pair.
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How Does Double Deep Racking Work?
Double deep racking works by loading the rear pallet position first, then placing a second pallet in front of it. Both positions are served from the same aisle, so the front position must be clear before the rear pallet can be retrieved.
The basic operating sequence is:
- Load the rear position: The reach mechanism extends to place the first pallet onto the rear supports.
- Load the front position: A second pallet is placed directly in front of the rear pallet.
- Retrieve the front pallet: The aisle-facing pallet is removed first.
- Access the rear pallet: Once the front position is clear, the truck can reach the pallet behind it.
Storing the same product in both positions can reduce the need to move an unrelated pallet simply to reach the required stock. A stock keeping unit, or SKU, identifies a particular product or product variant.
You should confirm that your handling equipment can reach the rear position and carry the required load at the planned storage height. Forklift compatibility needs to be assessed alongside the rack layout, rather than after the racking has been selected.
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Key Benefits of Double Deep Warehouse Racking
Double deep warehouse racking offers three main benefits: greater pallet density, scope to expand capacity within your existing premises, and efficient storage for products held in larger quantities. These benefits are strongest when your stock profile suits two-deep storage and your equipment can handle the layout effectively.
- Increase storage density: Reducing the number of access aisles allows more of your warehouse footprint to accommodate pallet positions. If floor space is limiting your capacity, this can help you store more stock without increasing the building area. The final gain should be calculated from a proposed layout that also allows for receiving, dispatch and other operational space.
- Manage the cost of capacity growth: Adding pallet positions within your current facility may help defer relocation or building expansion. However, you should compare the total project cost, including suitable handling equipment and any changes to workflows. A lower cost per pallet position is most useful when it also supports practical day-to-day operations.
- Organise high-volume SKUs: Two-deep storage works well when you regularly hold multiple pallets of the same product. Pairing compatible stock can make the reduced selectivity easier to manage, particularly when front pallets are routinely dispatched before rear pallets are needed.
Warehouse Applications for Double Deep Racking
Double deep racking suits warehouses that hold repeated pallet loads and can accommodate restricted access to rear positions. Common applications include cold storage, manufacturing, retail distribution and selected third-party logistics operations, although suitability depends on how stock moves through each facility.
- Cold storage and food distribution: Increasing pallet density can help you make better use of refrigerated storage space. The system is most practical when products are held in consistent pallet loads and compatible batches. For date-sensitive goods, you should assess expiry dates and retrieval sequences carefully, as rear pallets cannot be accessed independently.
- Manufacturing and FMCG: Manufacturers and fast-moving consumer goods (FMCG) businesses often hold multiple pallets of raw materials, packaging or finished products. Double deep storage can accommodate these repeated loads near production or dispatch areas, provided replenishment and retrieval patterns suit the arrangement.
- Retail and wholesale distribution: Bulk replenishment stock, promotional lines and seasonal products can suit two-deep storage when quantities are high enough to fill paired positions. If your operation involves frequent access to many different products in small quantities, selective racking may offer more convenient access.
- 3PL and contract logistics: Third-party logistics (3PL) providers can use double deep racking for customers with predictable, high-volume stock. Its suitability is more limited when customer requirements change frequently or many SKUs occupy only one pallet position. You can also consider allocating double deep storage to suitable product lines within a mixed racking layout.
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Featured Double Deep Racking Projects by Vinatech
Explore how Vinatech’s Double Deep Racking solutions maximise pallet storage capacity, reduce aisle requirements and improve warehouse space utilisation across different industries.
1. Food & Beverage Warehouse – Double Deep Pallet Racking
Vinatech implemented a Double Deep Pallet Racking System providing approximately 9,000 pallet positions within a 7,500 m² warehouse, featuring 10.5-metre-high racking, 5 storage levels and a 2-pallet-deep configuration.
The system achieves approximately 1,200 pallet positions per 1,000 m², reducing forklift aisle requirements while supporting efficient inventory organisation.
This project demonstrates how Double Deep Racking maximises storage density, optimises warehouse space and supports high-volume food and beverage distribution.
2. Manufacturing Warehouse – Double Deep Pallet Racking
Vinatech implemented a Double Deep Pallet Racking System providing approximately 8,200 pallet positions across an 8,000 m² warehouse, featuring 9-metre-high racking and a 2-pallet-deep storage configuration.
The system achieves approximately 1,025 pallet positions per 1,000 m², reducing conventional forklift aisle requirements while maintaining practical access to different inventory groups.
This project highlights how Double Deep Racking increases storage capacity, improves space utilisation and supports efficient high-volume logistics operations.
Why Choose Vinatech Australia for Double Deep Pallet Racking?
Choosing the right Double Deep Pallet Racking System requires more than maximising warehouse storage capacity. An effective solution should provide direct pallet access, efficient inventory management, safe forklift operations and flexibility for future expansion.
Vinatech Australia delivers customised double deep pallet racking solutions designed to optimise warehouse space, streamline pallet handling and support long-term operational efficiency.
- End-to-end project solutions: Comprehensive support from warehouse assessment, racking design and manufacturing to professional installation and after-sales service.
- 100% direct pallet accessibility: Double deep racking provides individual access to every pallet, enabling efficient stock picking, loading and retrieval without moving other pallets.
- Optimised warehouse layouts: Customised configurations maximise vertical storage space while maintaining appropriate aisle widths and forklift accessibility.
- Designed to Australian standards: Racking systems are designed in accordance with AS 4084:2023 requirements.
- Customised load configurations: Rack dimensions, beam levels and load capacities are tailored to pallet sizes, inventory requirements and warehouse operations.
- 2D and 3D warehouse designs: Detailed layouts help customers evaluate pallet capacity, aisle arrangements and material handling workflows before installation.
- Factory-direct manufacturing: Direct manufacturing supports competitive pricing, consistent product quality and flexible racking configurations.
- Flexible and scalable storage: Adjustable beam levels and modular designs accommodate changing inventory volumes, different pallet sizes and future warehouse expansion.
- Versatile industry applications: Suitable for logistics, FMCG distribution, manufacturing, retail, food and beverage storage, and e-commerce fulfilment.
- Australian-based support: Vinatech Australia provides local project coordination and after-sales assistance from 34 Paramount Blvd, Cranbourne West VIC 3977.
With extensive experience in warehouse storage solutions, Vinatech Australia provides double deep pallet racking systems that maximise space utilisation, ensure direct pallet accessibility and support efficient, scalable warehouse operations.
Vinatech Australia: Industrial Warehouse Racking – Warehouse Shelving Solutions
- Website: https://vinatech.com.au/
- Phone number: 0485 083 868
- 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.
