Pushback Pallet Rack: High-Density Multi-SKU Storage

Technology Overview

Peak Corp Pushback Pallet Rack is a high-density storage solution engineered to address the common warehouse challenge of maximizing storage capacity without completely sacrificing accessibility to a diverse inventory. Unlike drive-in systems that are best for single-SKU, deep-lane storage, pushback racking offers a balanced approach. It allows pallets to be stored multiple deep (2 to 5 pallets per lane) using a dynamic cart system, while crucially maintaining independent access to each lane and level. This design makes it possible to store a greater variety of SKUs in a condensed footprint compared to ultra-high-density systems. With the potential to store up to 90% more product than conventional selective racking, it is a powerful tool for optimizing warehouse space for operations with medium-depth, multi-SKU pallet storage needs.

How It Works

Core Principles

The system operates using nested carts on inclined rails within each storage lane. Pallets are loaded onto the front cart, and subsequent loads push the previous pallets further back into the lane. Each lane operates independently, allowing different SKUs to be stored in adjacent lanes.

Key Features & Capabilities

Configurable Lane Depth (2-5 pallets deep) allows customization based on inventory velocity and space requirements. Independent Lane Access ensures that each vertical level and horizontal lane can store a different SKU and be accessed without affecting others. High-Density Gain is quantified, with the system capable of providing up to 90% more storage than selective rack by utilizing depth.

Advantages & Benefits

The standout advantage is the substantial increase in storage density—approaching double the capacity of selective racking—within the same footprint. Unlike drive-in systems, it preserves accessibility to a variety of SKUs, offering greater flexibility for warehouses with diverse inventory. It optimizes space utilization effectively, making it a cost-effective solution for expanding storage capacity without facility expansion.

Implementation Considerations

Implementing this system requires planning for the additional vertical space needed to accommodate the cart mechanism at each level, which may reduce the total number of vertical storage positions in a building with fixed height. The choice of lane depth (2, 3, 4, or 5 deep) should align with the number of pallets typically stored per SKU to maximize efficiency and minimize "honeycombing." The cost is higher than for static selective racking but is justified by the significant density gains.

Use Cases & Applications

Ideal For

This system is ideal for warehouses and distribution centers that need to store multiple pallets of several different SKUs and are looking to significantly increase storage density beyond what selective racking can offer, but for which drive-in racking is too restrictive.

Conclusion

The Peak Corp Pushback Pallet Rack system offers an excellent compromise for operations seeking a meaningful boost in storage density without resorting to the single-SKU limitations of drive-in systems. By enabling 2 to 5 deep storage while keeping each lane independently accessible for different SKUs, it provides the flexibility needed for diverse inventory alongside significant space savings. For warehouses facing space constraints but handling a variety of products, this pushback solution represents a strategic investment that can dramatically increase capacity and improve space utilization, delivering a strong return through more efficient use of existing real estate.