Push Back Racking Project for Batch Storage – Vinatech Australia

• Project: High-Density Pallet Storage Solution
• Total Area: Approx. 8,000 m²
• Industry: Manufacturing & Distribution Centres
• System: Push Back Racking

Problem

For manufacturing and distribution operations handling multiple pallets per SKU, warehouse performance depends on the ability to store inventory efficiently while maintaining a consistent flow of inbound and outbound goods.

At this approximately 8,000 m² warehouse, the project focused on increasing pallet storage capacity within the existing footprint. The operation required a compact storage solution for batch inventory, with practical access for routine loading and retrieval.

The key requirements included:

• Increasing pallet capacity without expanding the facility
• Accommodating multiple pallets of the same SKU
• Organising inventory into dedicated storage lanes
• Reducing unnecessary forklift travel during pallet handling
• Maintaining accessible working aisles
• Supporting batch storage where strict FIFO rotation was not required

The challenge was to achieve higher storage density while keeping daily handling straightforward for forklift operators.

Solution

Vinatech Australia’s Push Back Racking solution combines multi-deep pallet storage with aisle-side loading and retrieval, providing a practical configuration for batch-based inventory.

The proposed system provides approximately 6,000 pallet positions across four storage levels, with each lane accommodating four pallets in depth. This arrangement uses both storage depth and available warehouse height to accommodate more inventory within the facility.

Push Back Racking allows incoming pallets to push previously stored pallets further into the lane. When the front pallet is retrieved, the remaining pallets move forward under gravity, bringing the next pallet to the unloading position. Forklifts handle goods from the working aisle without entering the rack structure.

Each lane follows a Last In, First Out (LIFO) sequence. Pallets of the same SKU are grouped within a lane, while separate lanes can accommodate different product lines. This makes the system suitable for batch inventory that does not require strict first-in, first-out access.

The proposed configuration incorporates:

• Approx. 6,000 pallet positions
• Four storage levels
• Storage lanes four pallets deep
• Dedicated lanes for individual SKUs
• Loading and unloading from the same working aisle
• Aisle access for routine forklift operations

The layout balances compact storage with access to individual lanes, helping the warehouse accommodate batch inventory without requiring direct access to every pallet.

Outcome

The proposed warehouse configuration is designed to increase storage capacity and simplify routine batch handling within the existing 8,000 m² footprint.

With an indicative capacity of 6,000 pallet positions, the system targets an approximately 30% increase in storage capacity compared with a baseline layout accommodating around 4,615 positions. This would allow the operation to hold more inventory without expanding the building.

Keeping pallet loading and retrieval at the lane entrance also supports a more consistent handling process. The project targets an approximately 15% reduction in average pallet handling time, subject to verification through comparable loading and retrieval tasks.

The anticipated operational benefits include:

• Approximately 30% more pallet storage capacity against the assumed baseline
• A target 15% reduction in average pallet handling time
• Better use of available warehouse height and storage depth
• Clearer inventory organisation through dedicated SKU lanes
• Reduced forklift travel within storage lanes
• A more consistent process for batch loading and retrieval
• Additional capacity to accommodate fluctuations in inventory volume

For manufacturing and distribution operations, the result is a compact, organised storage environment designed around multiple pallets per SKU. Final capacity and performance improvements will depend on the approved layout, pallet dimensions, load requirements and operating conditions.

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