Manufacturing Double Deep Racking Project – Vinatech Australia
Problem
Logistics and distribution warehouses need to balance two competing priorities: storing a large volume of pallets while maintaining sufficient accessibility for continuous inbound, replenishment and outbound operations.
For this 8,000 m² distribution warehouse, the customer required more pallet capacity without expanding the facility. A conventional Selective Racking layout would provide direct access to every pallet but require a larger number of forklift aisles, limiting the amount of floor space available for storage.
At the same time, a very high-density system such as Drive-In was not ideal for an operation that still required regular access to a broad range of inventory.
The customer therefore needed to:
- Increase pallet capacity within the existing 8,000 m² footprint
- Reduce floor area dedicated to forklift aisles
- Maintain practical access to a broad inventory range
- Support frequent inbound and outbound pallet movements
- Make better use of available warehouse height
- Provide a straightforward solution for high-volume logistics operations
The challenge was to achieve greater storage density without moving to a fully high-density storage system that would significantly restrict pallet accessibility.
Solution
Vinatech implemented a Double Deep Pallet Racking System, storing pallets two positions deep instead of one pallet deep as in conventional Selective Racking.
By arranging rack rows back-to-back in a double-deep configuration, the system reduces the number of forklift aisles required across the warehouse. The recovered floor area can then be converted into additional pallet storage.
The multi-level structure reaches approximately 9 metres in height, providing around 8,200 pallet positions across the 8,000 m² facility, equivalent to approximately 1,025 pallet positions per 1,000 m² of warehouse floor area.
The system combines:
- Approx. 8,200 pallet positions
- Approx. 9 m racking height
- Two-pallet-deep storage configuration
- Multi-level vertical storage
- Reduced aisle requirements compared with Selective Racking
- Dedicated storage locations for different inventory groups
- Access using suitable reach-truck or double-deep handling equipment
The configuration therefore provides a middle ground between conventional Selective Racking and higher-density deep-lane systems.
Outcome
The Double Deep configuration increased overall pallet capacity by approximately 30% compared with a Selective Racking layout, without requiring additional warehouse floor area.
Rather than maximising density at the expense of day-to-day accessibility, the system provides a more balanced storage model for logistics operations. More inventory can be consolidated within each storage zone, while pallets remain accessible through clearly defined operating aisles.
The project delivered:
- Approx. 8,200 pallet positions within 8,000 m²
- Approx. 30% increase in storage capacity
- Approx. 1,025 pallet positions per 1,000 m²
- Better utilisation of the available warehouse height
- Fewer forklift aisles compared with conventional Selective Racking
- More efficient use of the existing warehouse footprint
- Higher inventory concentration within each storage zone
- A practical balance between storage density and pallet accessibility
For the customer, Double Deep Racking provides an effective step up from conventional Selective storage: more pallets within the same warehouse, fewer aisles and greater storage density without moving to a fully deep-lane storage model.
Testimonial
“The Double Deep system has allowed us to increase pallet capacity without expanding the warehouse. We are able to store more inventory within each storage zone while maintaining the level of accessibility required for our daily logistics operations. It provides a good balance between capacity and operational flexibility.”
– Warehouse Operations Manager, Logistics & Distribution
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
