Push Back Racking
Increase your pallet capacity by up to 35% without expanding your footprint. By storing pallets two deep, double deep racking provides a high-density setup for high-volume operations—allowing you to store more inventory in the same space while keeping pallets accessible.
What is Push Back Racking?
Push back racking relies on a series of nested carts that ride on inclined steel rails. When loading, the forklift pushes the front pallet back to make room for the next one. When unloading, gravity automatically glides the next pallet forward to the picking face.
Because this gravity-fed racking system utilizes nested carts, it provides direct access to stored goods without the forklift ever entering the rack structure. To improve inventory visibility, carts are typically color-coded, allowing operators to instantly see how many pallets remain in a lane.
Key Operational Facts:
- Depth: Configurations typically range from 2 to 6 pallets deep.
- Inventory Flow: Operates on a LIFO (Last In, First Out) basis per lane.
- Equipment: Unlike more restrictive setups, a push-back pallet rack system can typically be operated using standard counterbalance forklifts.
- Pallet Quality: Requires structurally sound pallets; broken bottom boards can interfere with the rolling cart mechanism.
Key Features & Benefits:
- Reduced Rack Damage: Since forklifts stay in the aisle, uprights are less exposed to impacts than in drive-in systems.
- Labor Efficiency: Centralized pick faces reduce “travel time,” increasing pallets moved per shift.
- Selectivity vs. Density: Offers the density of a drive-in system with the SKU selectivity of a 2-deep system.
Where Double-Deep Racking Shines
Double-deep racking is highly effective when your inventory movement is planned, consistent, and volume-heavy. Here are the primary use cases:
High-Volume, Same-SKU Storage:
This system is perfect when you have multiple pallets of the same product. Because the front pallet doesn’t block access to a different SKU, you reduce unnecessary reshuffling while maximizing cubic space. (Examples: Boxed furniture, sofas, tables, or bulk packaged components).
Facilities with Limited Floor Space:
Ideal for urban warehouses, leased facilities, or distribution centers nearing capacity. When you cannot expand your footprint but need to add pallet positions quickly, fewer aisles mean more rack rows and better use of your horizontal space.
Seasonal or Buffer Storage:
This high-density pallet racking configuration is excellent for buffer inventory that doesn’t require constant, everyday access. Slower-moving inventory can be stored securely behind fast movers, reducing congestion in your active selective rack zones. (Examples: Seasonal furniture lines, promotional inventory, or safety stock).
Full-Pallet In / Full-Pallet Out:
Double-deep racking is typically not ideal for individual piece-picking. Instead, it is an excellent pallet storage solution designed for bulk replenishment stock or reserve inventory that eventually feeds your pick modules.
Specialized Solutions for Your Sector
E‑Commerce
High-density reserve storage that keeps fast-moving pick faces replenished.
Manufacturing
Ideal for batch-produced components and raw material storage.
Big & Bulky
Maximizes cubic space for furniture, appliances, and large-format goods.
Food & Beverage
The standard for cold storage/freezers where maximizing every inch of temperature-controlled space is critical.
Is Push Back Racking Right for You?
At USSI, we ensure your system is engineered for your specific inventory flow and existing equipment.
It is a Perfect Fit If:
- You store multiple pallets (2 to 6) per individual SKU.
- Your inventory flow naturally aligns with LIFO (Last In, First Out) at the lane level.
- You want high density but need more selectivity (more SKU faces) than drive-in racking allows.
- You want to utilize your existing standard counterbalance forklifts.
You Should Look at Alternatives If:
- You require strict FIFO (First In, First Out) rotation for date-sensitive goods. See: Pallet Flow Rack
- You only have 1 pallet per SKU and need 100% direct access at all times. See: Standard Rack
- You are storing massive volumes of a single SKU and do not need lane-level selectivity. See: Drive-In Rack
Ready to Optimize Your Storage Space?
USSI handles the layout design, engineering, and physical installation of every push-back pallet rack system we deploy. Projects range from retrofitting active distribution centers to planning seasonal overflow and laying out new warehouse facilities from the ground up. Each system is customized based on your specific pallet weights, depth requirements, and facility footprint.