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How to choose a storage system according to your operations | Storage system
Choosing a storage system isn’t just about “putting up racks and calling it a day.” It’s about aligning the warehouse with your actual operations: how goods arrive, how orders are prepared, the rotation of each SKU, the handling equipment you use, and the risks you want to minimize. When the system fits, you gain capacity, speed, and safety. When it doesn’t, bottlenecks, product damage, structural impacts, and hidden costs appear.
Define your operational “snapshot” before comparing systems
Before looking at catalogs, define these points:
- Load unit: pallet, container, box, reel, hanging garments, long profiles, etc.
- Rotation: high, medium, or low (and whether there is seasonality).
- FIFO / LIFO: whether you need stock rotation by age (food, pharma, expiration dates) or not.
- Order preparation: by box, unit, batch, or full pallet.
- Equipment: pallet jack, reach truck, counterbalance, VNA, trilateral, AGV/AMR, etc.
- Clear height and restrictions: sprinklers, lighting, installations, internal regulations.
- Safety: traffic, aisles, protections, inspections, and maintenance.
Typical systems and when they fit
Conventional Pallet Racking (Selective)
The most flexible system when you need direct access to every pallet. Ideal for a wide variety of references and mixed rotations. The trade-off is that it consumes more aisle space and, therefore, offers lower density.
Compact Storage (Drive-in, Push-back, Mobile)
When your priority is density (many pallets per square meter) and you work with batches or high-volume references. It is key to define whether you work with FIFO or LIFO and evaluate the operational risk of maneuvering inside the channel.
Pallet Flow Racking (Gravity)
Perfect if you are looking for FIFO, speed, and aisle reduction. Widely used in cold rooms, food industries, and order preparation. It requires high pallet quality, slope control, and good maintenance to avoid jams.
Cantilever (Long loads)
For profiles, pipes, boards, or irregular loads. The key is sizing the arms, bracing, and protections against forklift impacts, especially in high-rotation areas.
Picking (Manual or Semiautomatic)
If preparation is by unit/box, picking rules: accessibility, ergonomics, signaling, routes, and replenishment. Here, it is common to combine levels: picking at the bottom and palletized reserve at the top.
Automation (Miniload, Stacker Cranes, Shuttles)
When you need high performance, traceability, and operational stability. It requires a fine-tuned analysis of flows, peaks, maintenance, and redundancies. It’s not just about “installing an automatic system”: it’s about redesigning processes.
Comparative Table (Guideline) for faster decision-making
| System | Access | Density | Speed | Best for | Critical Point |
|---|---|---|---|---|---|
| Conventional | Direct | Medium | Medium | Many SKUs and flexibility | More aisles |
| Compact | By channel | High | Medium | Few SKUs with volume | Maneuvering risk |
| Flow (FIFO) | Exit face | High | High | Expirations / High rotation | Maintenance and pallet quality |
| Cantilever | Direct | Medium | Medium | Long loads | Sizing and protections |
| Picking + reserve | Very High | Medium | High | Order preparation | Replenishment and order |
| Automated | Controlled | Very High | Very High | Performance and traceability | Flow design and maintenance |
Typical mistakes when choosing a storage system
- Choosing based only on capacity and forgetting flows, aisles, and order preparation.
- Not sizing equipment: forklifts and turning radiuses incompatible with the layout.
- Not planning protections: uprights and frames exposed to impacts.
- Ignoring the state of structures: expansions, relocations, or configuration changes without technical validation.
- Leaving safety for last: signage, training, inspections, and maintenance must be part of the design.
Frequently Asked Questions
What is the best storage system for pallets?
It depends on whether you need direct access to each pallet (conventional) or maximum density per reference (compact or flow). Rotation, the number of SKUs, and the type of forklift dictate the decision.
What system is best if I work with FIFO?
Usually flow racking systems or configurations that ensure entry on one side and exit on the other. In products with expiration dates, FIFO is usually an operational requirement.
Can I combine picking and palletizing in the same installation?
Yes. This is a very common solution: picking on lower levels and palletized reserve on upper levels, optimizing routes and replenishment.
How often should I check my racking?
In addition to frequent internal checks, a periodic technical inspection by expert and independent personnel is recommended to detect deformations, damage, and risks before they become an incident.
If you are considering redesigning your warehouse or setting up a new one and want to know exactly how much capacity you need, at Noega Systems, storage systems, we can help you put clear figures and plans on the table before you outgrow your space in two years. Contact us
