Dense Storage Strategies for Modern Indian Warehouses

The growth of omnichannel, the increasing spending power of Indian consumers, and several other factors are driving up the pressure on warehouses to operate with more speed and efficiency. This means that in their bid for warehouse optimisation, manufacturers and logistics players are choosing between dense and standard storage systems. A crucial aspect of dense storage systems is racking.

Dense storage racking is designed to utilise vertical space in addition to floor space in a warehouse and increase overall storage capacity. Customised designs and storage configurations in high-density pallet storage racks markedly enhance space efficiency.

How exactly does a dense storage strategy create business impact?

Optimisation: Dense storage optimises storage capacity by adding more shelves and storage locations. By doing this, businesses with high-volume inventory achieve more in less space and save precious real estate.

Accessibility: The system also increases the efficiency of operations through more systematic storage and retrieval. Intelligent organisation and retrieval mechanisms ensure that products are easily accessible, contributing to streamlined warehouse processes and faster order fulfillment.

Other factors: Scalability, less labour dependence, enhanced order fulfillment efficiency, better organisation, and tracking are some other benefits of a strategic move to dense storage systems.

Which industries and sectors need dense storage systems?

Typically, most businesses stand to benefit from adopting dense storage strategies in warehouses. However, it is best suited for businesses that need cold storage facilities, see high-volume inventory movement or seasonal peaks, need efficient management, have perishable goods, etc.

For instance, high-density racking systems in the pharmaceutical industry need accurate and timely product retrieval and often operate in temperature-controlled environments. By keeping the need for space compact, energy efficiency is achieved - resulting in cost savings as well. Moreover, high-density systems inherently enhance product safety and traceability through security features and compliance with regulatory standards. The compatibility with cleanroom environments and adaptability to evolving storage needs help with organised batch management in pharmaceutical storage facilities.

What are some popular systems of dense storage?

Mobile Pallet Racking (MPR): A cutting-edge storage solution suitable for both new and existing buildings. It features a pallet racking structure supported by a mobile undercarriage system that travels along rails installed on the floor. The motorised undercarriage, operated by programmable PLC units, guarantees precise and efficient movement while maximising storage space utilisation by creating a single open aisle at any given time. Equipped with a user-friendly remote control, an extensive array of accessories, and safety features for seismic conditions, the Godrej MPR solution ensures effortless system operation and movement.

Shuttle Pallet Racking: A collision-free system, it uses a shuttle for loading and unloading. It delivers about 30% more storage capacity than wide-aisle pallet racking systems. The system eliminates the need for an aisle or for even MHEs to enter the system - reducing the risk of accidents.

Drive-in Racking: Godrej’s drive-in systems consist of interconnected blocks without aisles designed for bulk storage of palletised loads, resulting in maximum utilisation of cubic space. Each storage bay is only one pallet wide and designed to store pallets multiple levels high with variable depth to suit the need. The forklift truck can drive right into the storage bay and place or retrieve the pallets as required. Special guide rails ensure safe, fast and accurate positioning of Forklifts.

Pallet Flow Racking: As the name suggests, the system enables pallets to move along metal rollers via gravity. So, by default, this system operates on FIFO (First In, First Out). This system stores pallets of multiple high and multiple deep with one type of SKU per level.

Push Back Racking: Another form of dense storage system where the sequence of pallet loading is done by pushing the first pallet back. Consequently, after the first pallet, the loading of pallets is through “MHE Push”. In this system, pallet carts are fitted with rollers because the sequence of pallet availability for unloading is by gravity. Push back systems do loading and unloading on the same end, making LIFO (Last In, First Out) the default. This system is designed to store pallets of multiple high and multiple deep with each level dedicated to one type of SKU only.

Contrary to the misconception that dense storage sacrifices accessibility, modern racking systems are designed with efficiency in mind - allowing businesses to store more inventory within the same footprint. With the evolving needs of business today, the decision to implement dense storage racking in a warehouse is a strategic move that can significantly impact costs, operational efficiency, storage capacity, and overall productivity.