Custom Drive-In Rack for Mattress Storage – A Case Study 

Solutions at a Glance

  • Services Provided: Design, Project Management, Permitting Support
  • Products Provided: 2-Deep Drive-In Racking System
  • Location: Phoenix, AZ

Concern: Not Enough Storage Space

A mattress manufacturer needed to downsize from a 270,000 sq. ft. facility to a 130,000 sq. ft. facility while maintaining the same volume of products.   Mattress Pallets

With this move came the question of how they can store the same stock levels from their existing facility in their new facility, which is approximately half the size.

The company’s existing storage system utilized selective pallet rack at three pallets high with 18’ aisles. Because the company wanted to utilize existing lift equipment, the aisle widths could not be significantly reduced from 18’. Therefore, a denser very narrow aisle selective rack layout would not be feasible. 


Solution: Custom Drive-In Rack Design  

The company hired REB Storage Systems to design a new material handling system for their smaller warehouse. To increase storage capacity in the new facility, REB suggested a high-density storage solution, such as (2) deep drive in. However, due to the widths of their customized pallets per mattress size (86” king mattress pallets, 82” queen mattress pallets, double, and twin), a standard drive-in rack design would not be feasible. 

For that reason, REB developed a customized solution for the company that utilizes the design of a structural two-wide pallet style drive-in pallet rack but designed to accommodate each of the company’s customized pallets widths. The design incorporates longer drive-in support arms by utilizing cantilever rack. This allows for king, queen, double, and twin mattress pallets to be stored. 

2-Deep Drive-In Racking System

Outcome: High-Density Storage Facility 

The company now has an optimized facility that can accommodate their unique inventory. The result was a layout that shrunk their footprint by half.  

As an experienced systems integrator, REB offers comprehensive services, including design, subcontractor and product procurement, project management, permitting support, and installation. This allows the company to have one point of contact throughout the process of building the storage system.

How You Can Increase Your Storage Density  

If you need a material handling system to increase your storage density, contact REB today.   

Our dedicated team of material handling experts will provide a solution that will optimize your warehouse storage. We are highly experienced in identifying inefficiencies and implementing improved systems.  

We’d appreciate the opportunity to help you further, whether that be more information or a quote. Fill in the contact form on this page or call us at (800) 252-5955 to get in touch with a REB representative.  

Share this post:

Submit Your Inquiry

  • This field is for validation purposes and should be left unchanged.


Brian Dubin

All Products Automotive, Inc.

“We have been a customer for over 15 years. REB offers a good selection of products at great prices. They are an excellent source of materials along with suggestions and information on a variety of storage issues."

Bruce Moulton

Harrington Industrial Plastics

“REB is by far my favorite vendor, the customer service and dedication to making sure every order is complete and on time. Fantastic communication, and an absolute pleasure to work with.”

Gary Rothschild

Epko Industries

“First time customer and REB provided excellent service and competitive pricing. Would use them again.”

Elliot Sneen

Cabernet Corporation

“Great customer service with an accurate storage system!”

Richard Steed

Pacific Storage Company

“We have used REB Storage Systems for a number of years and will continue to do so in the years to come. Their entire staff are wonderful to work with and provide a seamless installation from beginning to end. Their focus to detail and quality installation has been a valuable resource to our company.”

Tom Beckermann

Felling Trailers Inc.

“REB Storage Systems provides a high quality product with the best customer service in the industry, no matter the volume of products we buy.”

Blog Topics By Category

Blog Topics By Industry

REB Stats