Double Deep Racking Project for Distribution – Vinatech Australia
Problem
High-volume distribution operations often need to hold substantial quantities of reserve inventory while keeping products available for regular replenishment and dispatch.
In this project, the available storage footprint was relatively constrained compared with the volume of palletised goods the warehouse needed to accommodate. A conventional single-deep layout would require more aisles, reducing the proportion of floor area available for actual pallet storage.
At the same time, the operation did not require the extreme storage depth of a Drive-In or Shuttle system. The customer needed a configuration that could provide more pallet capacity per rack block while retaining dedicated access aisles for daily handling.
The key requirements were:
- Increase pallet capacity within the existing storage footprint
- Accommodate higher stock volumes without warehouse expansion
- Make greater use of the available vertical clearance
- Reduce the floor area occupied by additional rack aisles
- Maintain defined access routes for pallet handling
- Provide sufficient reserve inventory for high-volume distribution cycles
The challenge was therefore to achieve a higher storage concentration without converting the warehouse into a fully high-density, deep-lane storage facility.
Solution
Vinatech implemented a Double Deep Pallet Racking System, allowing pallets to be stored up to two positions deep on either side of the operating aisle.
The actual installation shows long, continuous rack rows arranged around clearly defined access aisles. Compared with conventional Selective Racking, this configuration places a greater number of pallet positions behind each rack face, allowing the warehouse to concentrate more inventory within each storage block.
The rack structure rises to approximately 9.5 metres, with around 5 pallet storage levels configured vertically.
Based on the completed layout, the estimated project specifications are:
- Warehouse area: approx. 4,500 m²
- Racking height: approx. 9.5 m
- Storage levels: 5
- Pallet capacity: approx. 5,200 pallet positions
- Storage intensity: approx. 1,155 pallet positions per 1,000 m²
- Storage configuration: up to 2 pallets deep
- Long Double Deep storage rows
- Dedicated access aisles between rack blocks
An important feature of the design is the combination of depth and height. Rather than relying only on additional floor-level positions, the warehouse uses five vertical storage levels together with two-deep pallet placement to generate capacity from the available cubic space.
Outcome
The completed system provides approximately 5,200 pallet positions within a 4,500 m² warehouse, equivalent to around 1,155 pallet positions per 1,000 m² of total warehouse area.
The Double Deep configuration enables more reserve inventory to be positioned within each storage block while preserving dedicated aisles for pallet handling.
For a high-volume distribution operation, this creates a practical buffer between incoming stock and downstream demand.
Key outcomes include:
- Approx. 5,200 pallet positions
- 5 storage levels across an approx. 9.5 m structure
- Approx. 1,155 pallet positions per 1,000 m²
- 2-deep pallet storage for higher-volume inventory
- Better utilisation of available warehouse height
- Fewer aisles required than an equivalent single-deep configuration
- More reserve inventory accommodated within the same footprint
- Defined access aisles maintained for regular pallet handling
- Reduced need to expand the warehouse simply to create additional pallet positions
Rather than pursuing maximum storage density, the system creates a middle ground between conventional Selective Racking and deeper high-density storage. The warehouse gains additional capacity from both rack depth and vertical space while retaining a structured aisle-based operating model.
Testimonial
“The new racking configuration gives us more room for high-volume inventory without requiring additional warehouse space. By increasing storage depth and making better use of the available height, we can maintain a larger stock buffer while keeping dedicated aisles for daily pallet handling.”
– Distribution Warehouse Manager
Vinatech Australia – Pallet Racking & Industrial warehouse racking 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
