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 30–40%.
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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- Pallet Racking Systems – For Storage Solutions Australia
- Pallet Flow Racking Systems – Maximize Warehouse Productivity with FIFO
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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.
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.
Vinatech sees manufacturing and FMCG as highly suitable sectors for Double Deep Racking because they typically combine high pallet volumes with moderate selectivity requirements.
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.
Double Deep Racking helps these businesses create higher-density reserve storage while still maintaining a controlled replenishment process. This is particularly valuable for distribution centres in outer metropolitan areas serving Sydney, Melbourne, or Brisbane, where floor space is becoming increasingly costly.
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.
Key Benefits of Double Deep 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.
Compare the Double Deep Racking system with other types of racking.
Vinatech Australia’s double deep racking offers an effective balance between storage density, product accessibility, and investment cost.
Double Deep Racking offers an effective balance between storage density, product accessibility, and investment cost. Compared with other common warehouse racking systems, this solution stands out for its ability to maximise storage capacity while still maintaining practical day-to-day operation.
| System | Storage Density | Selectivity | Handling requirement | Best fit |
|---|---|---|---|---|
| Selective Pallet Racking | Moderate | Highest | Standard forklift access | High SKU variety, fast access |
| Double Deep Racking | High | Medium | Reach truck / extended reach forklift | Repeat SKUs, batch storage, reserve stock |
| Drive-in Racking | Very high | Low | Forklift enters rack | Bulk homogeneous stock, cold storage |
| VNA Racking | High | High | Specialised VNA equipment | Maximum access in narrow aisles |
Important Considerations for Double Deep Systems
As your expert warehouse partner, we believe in providing a complete picture. To ensure Double Deep Racking is the right fit for you, Vinatech helps you navigate these key considerations:
- Specialised Forklifts: This system requires a deep-reach or telescopic forklift. Our design team will work with you to ensure your layout provides adequate clearance and is compatible with your material handling equipment.
- LIFO Inventory Management: The Last-In, First-Out (LIFO) access method is a core feature. We will help you analyse your inventory to confirm this system aligns with your stock rotation needs, making it ideal for non-perishable goods or products with uniform batch codes.
Engineered for Australian Standards and Safety
Your team’s safety and the security of your inventory are non-negotiable. Vinatech Australia is committed to delivering solutions that meet the highest local standards.
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.
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Why Choose Vinatech Double Deep Racking?
For Australian businesses looking to increase pallet storage density without compromising safety or long-term operational efficiency, Vinatech Australia positions its solution as a complete storage solution rather than simply a racking product.
Vietnam-based manufacturer with global capability
Vinatech combines manufacturing capability in Vietnam with the scale of two large factories covering a total area of nearly 50,000 m². Vinatech’s racking systems have been supplied to a range of international markets, including Thailand, the Philippines, Cambodia, Laos, South Korea, the United States, and Australia.
This capability is further strengthened by Vinatech Australia’s local presence. The company has a branch in Cranbourne West, Victoria, established to support product display, design consultation, and technical assistance for Australian customers.
AS4084 compliant systems
For warehouses in Australia, compliance is essential. All Vinatech racking systems are certified to AS4084-2023 standards. In addition to compliance, Vinatech also presents its systems as quality-controlled products backed by a comprehensive warranty.
Custom warehouse design
Vinatech Australia provides free consultation, free warehouse surveys, and free 3D design drawings as part of its delivery process.
This is especially important because double deep racking only performs at its best when the system is designed to suit pallet specifications, storage depth, forklift operating requirements, available floor space, and the actual workflow of the warehouse.
Installation & after-sales support
Vinatech Australia provides nationwide installation, periodic maintenance, and a complete end-to-end process covering consultation, layout design, forklift planning, professional installation, and final handover.
This is particularly important for Australian businesses looking for a clear, coordinated implementation process with reliable support after the system is in operation.
Get More From Your Warehouse Space Today
Stop letting empty aisles limit your growth. Vinatech’s Double Deep Racking is the smart, safe, and cost-effective way to unlock your warehouse’s true storage potential.
Contact our expert team for a free consultation to see if Double Deep Racking is right for your business. Request a quote today and discover how much more you can achieve with your existing 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.
Double deep racking allows access using specialised forklifts without entering the rack, while drive-in racking requires forklifts to drive into the structure, offering higher density but lower selectivity.
The load capacity depends on beam design, upright strength, and system configuration. It is typically designed for heavy-duty pallet loads and must comply with Australian Standard AS 4084.
Double deep racking works best in warehouses with large volumes of similar products, consistent pallet sizes, and layouts that prioritise storage density over direct access.
Double deep racking is not ideal for strict FIFO systems because rear pallets can only be accessed after removing the front pallets.
Yes, double deep racking is suitable for LIFO operations where the last pallet stored is retrieved first.
Installation time depends on warehouse size and system complexity, typically ranging from several days to a few weeks.
It is best suited for high-volume, low-SKU goods with consistent pallet sizes, such as packaged products, bulk items, and non-perishable inventory.
Regular visual inspections should be conducted weekly or monthly, with formal inspections performed annually to ensure compliance and safety.
Double deep racking systems are highly durable, constructed from heavy-duty steel designed for long-term industrial use.
The lifespan typically ranges from 10 to 20 years or more, depending on usage, maintenance, and operating conditions.
Double deep racking is commonly used in distribution centres, manufacturing warehouses, cold storage facilities, and logistics operations handling large pallet volumes.
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