How can I store more product in my warehouse?

So you want to get on top of your storage issues and make the absolute best use of your warehouse space…there are so many different ways you could design your warehouse space & so many options for racking systems, we completely understand if the decision can be put into the ‘too hard’ basket.

Let us help!

First, have a look at your current storage. How many pallets are in storage for each product line or type?

Once you have a breakdown of how many pallets need to be stored, it is much easier to design a storage system to best suit you.

You have probably heard of Pareto’s Principle…..around 80 % of your outgoing product is in 20% of your product lines.

That means, not all product lines are to be stored or treated equally. You need to prioritize storage & access for those 20% of your product lines that are the fastest moving.

But you also need to store all your other product, but maybe in areas that are further from your dispatch / packing zones, or for example on the top beam level of your racking, rather than at ground or eye height.

Here are some helpful tips & ideas on how to best store your different product lines.



Your main options are:

Bulk stacking (No racking systems)

You do not require racking for this storage method.

Best if you:

  • Have very few differing product lines
  • Have many pallets of each product line
  • Have a large warehouse floor space available
  • Good for light product as product requires stacking – heavy products can cause crushing of pallets underneath.

Because you don’t need to purchase any additional storage (racking) systems, this can be an economical option if your products & warehouse fit the criteria above.

Bulk stacking obviously does not make the most of your vertical warehouse “air” space, as there is a limit to how many pallets can be safely stacked.

Wasted air space & less product access is the main limitation for bulk stacking as a storage method.

Drive-in Racking

Best if you:

  • Have products with a long “shelf life” i.e will not deteriorate or perish over a longer period of time. Drive in racking works on a LILO prinicpal – Last in, last out.
  • Have a lot of pallets of the same product line.

Drive-In racking means you can utilize your warehouse’s vertical space as well as floor space.

Drive-in racking is still a very economical option, but care needs to be taken by forklift operators when moving/adding pallets or you can cause damage to your product if due care isn’t taken.

Pallet flow Racking

Best if you:

  • Have product with “best before” or expiration dates, as this racking system operates on a FIFO principal – First in, first out. The pallet entry point is at the back of the racking to allow the “oldest’ pallet to be at the front for stock picking.

Pallet flow racking is an excellent use of your warehouse’s vertical space as well as floor space.




Your main options are:

Selective Pallet Racking

Best if you:

  • Need an economical & versatile system that can be accessed by various lift trucks at any entry point
  • Have product with expiration dates, or product you need to access quickly – this racking system works best in FIFO applications, but uses more space per pallet then a pallet flow system.
  • Need to be able to see all your palletised product easily.

Selective pallet racking is the most basic form of racking and the most well-used.

Double-Deep Racking

Best if you:

  • Need to reduce the amount / size of aisles to better utilise your floor space.
  • Don’t need immediate access to all your pallets – this racking system works on a FILO principal but obviously not to the extent of a Drive-in Rack system.
  • Are prepared to use a special deep reach lift truck to place a pallet in the deeper pallet position and also to position it closer to the aisle.

Double-deep racking allows two selective racks to be pushed together to make the storage area twice as deep. Great for utilising valuable air space and minimising use of floor space.

Push Back Racking

Best if you:

  • Don’t have product with or expiration dates, as this racking system operates on a LIFO principal – Last in, first out. The pallet entry point is at the front of the racking.
  • Want a system similar to pallet flow racking but with a LIFO application – allows you to store pallets 2 – 5 deep.

Push back racking is not as economical as other storage systems however still makes excellent use of valuable warehouse space.



The above types of storage systems & racking are some of the most common and popular amongst our clients, you do have other options available. No two clients will have the same storage needs, so the systems can be tailored to your exact needs.

Cantilever Racking

Best if you:

  • Need to store extra long, oddly shaped or bulky items such as timber lengths, steel lengths, extrusion, pipes, sheet metal, board packs etc

Cantilever racking is easily customised to your requirements: rows of uprights can be any length required. The cantilever arms can be modified flexibly for stored goods with different heights and loading requirements.


Warehouse Mezzanines

Best if you:

  • Have a lot of wasted vertical air space and would like to add a second floor for additional storage or office space without the hassle of council approvals & building works
  • Would like to take the floor with you if you ever move – our mezzanines can be designed so you can simply dismantle & re-install at your new location

Mezzanines can have a multitude of uses and can at least double your available floor space.


There are many different ways you can store products in your warehouse, but not all are right for your operations. If you need help designing a complete storage solution to suit your product lines & warehouse areas, we’d love to hear from you.

Call 1300 551 281 or email to speak to an expert in space today!