Pallet Flow Rack + Custom Pallet Design for Scaffolding Storage – A Case Study

A scaffolding manufacturer partnered with REB to get a storage system that could improve product flow, reduce damage incurred during storage, and increase storage density. REB designed a pallet flow rack system with custom pallets that allowed the scaffolding to be stored upright, more secure, and picked individually.

Solution at a Glance

A scaffolding manufacturer partnered with REB to update their storage capabilities with pallet flow racking and custom pallets. These solutions would be designed around the unique shape and handling requirements of their inventory.

• Products: Pallet Flow Rack, Custom Pallets
• Services: Design
• Industry: Manufacturing
• Location: Oswego, IL
• Number of Projects REB has Completed for Customer: 17

Concern: Inefficient Ground Storage Reduced Capacity and Caused Product Damage

The manufacturer’s existing storage method was to have the scaffolding staged in lanes directly on the warehouse floor, with pieces leaning against one another. While this was a straightforward and cheap storage method, it created three operational problems: inefficient product rotation, product damage, and too much lateral storage space.

Since the scaffolding was stored in a first-in, last-out arrangement, products positioned toward the back of a lane were rarely picked. Over time, friction between the stored sections of scaffolding caused the paint to rub off. When these sections were eventually picked, they often required repainting before use.

Their storage method also required a substantial amount of floor space. By keeping the scaffolding at ground level rather than using the available vertical space, the manufacturer was limiting the amount of inventory that could be stored within their facility.

For an operation storing a large quantity of relatively few different SKUs, improving product rotation and increasing storage density would address all of these issues simultaneously. The company needed a system that would provide FIFO access while accommodating the shape and size of the scaffolding.

Solution: Pallet Flow Rack with Custom Pallets for High-Density FIFO Storage

REB’s design team analyzed the inefficiencies that were being experienced and the scaffolding dimensions and came up with a two-part solution.

15-deep Pallet Flow

REB evaluated the manufacturer’s inventory and storage requirements and determined that pallet flow rack was well suited to the application. This type of system provides high-density storage while providing FIFO product flow. Pallets can be loaded from the backside of a lane and flow toward the picking side on inclined rollers or wheels. When the front pallet is removed during picking, the next pallet moves into position for picking.

This approach allows the manufacturer to rotate their inventory in the order it was stored while making better use of vertical space. Pallet flow is also ideal for facilities that store multiple pallets of the same SKU, making it a great choice for a company that stores a large quantity of relatively few products.

The completed system consists of four bays of pallet flow racking. Each bay has two levels of storage and is 15 pallets deep. In total, this allows the company to store 120 pallets of scaffolding.

Custom Pallets Designed for Scaffolding Storage

Standard pallets presented another challenge for this solution. Pallet flow systems require pallets that can move smoothly through the lanes. The manufacturer’s scaffolding could not just be laid flat on a standard pallet without becoming unstable.

One option the company considered was shrink-wrapping the scaffolding to a conventional pallet. However, doing so would have made the picking of individual pieces inefficient. Employees would then have to remove the shrink wrap, pick the required pieces, and then rewrap the remaining inventory on the pallet each time a pallet was accessed.

REB’s project designers instead designed a custom pallet specifically fit for this solution. The design of the pallet featured a metal structure mounted to the top of the pallet with slots along each side. With this design, the legs of the scaffolding could be positioned in these slots, allowing them to remain upright and organized while stored on the racking. Upon completion of the design, a prototype pallet was made and tested on a pallet flow racking system to ensure that the pallet would properly move within the system.

This configuration also allowed employees to remove only the amount of scaffolding required for an order rather than handling an entire pallet load. The result was a pallet design that addressed both the physical stability requirements of the product and the manufacturer’s need for flexible piece-level picking.

Outcome: A Safe and Higher-Density FIFO Scaffolding Storage

By working with REB, the customer was able to get a customized solution that addressed the areas of concern they had with their original storage method, while also improving several aspects of their facility’s operations.

Increased Storage Density

The pallet flow rack system uses vertical storage space that was previously not used when the scaffolding was stored on the warehouse floor. The completed configuration provides two lanes high and 15 pallets deep across four bays, allowing significantly more scaffolding to be stored in the same space.

Increased Storage Capacity

Between the customized pallets and the 2-high 15-deep storage lanes, the company was able to double their storage capacity to 120 pallets of scaffolding. The use of vertical space and the organized storage of the scaffolding makes it so the company can store more products.

Improved Product Rotation

The previous ground-level storage resulted in LIFO product movement, minimizing how frequently inventory at the back was used. Pallet flow changes the product flow of the scaffolding to FIFO which allows for continuous rotation of the inventory and improved inventory management.

Reduced Product Damage

The custom pallets provided the scaffolding with a safe, secure, and stable base for them to be stored on. The pallets allow them to remain stood upright and separated rather than leaning against one another on the warehouse floor. This reduces the friction that had previously caused paint to rub off during storage. The reduced damage also makes it so the scaffolding does not need to be repainted.

More Flexible Picking

The custom pallet design allows employees to remove only the scaffolding needed rather than having each pallet stored as a single indivisible load. This eliminates the repeated shrink-wrap handling that would have been required if the scaffolding had been secured to a standard pallet.

Do You Store Items that Require a Custom Storage System?

Products with unusual dimensions, shapes, or handling requirements do not always fit conventional storage methods. REB can evaluate your inventory, storage requirements, and available space to design a material handling system around the way your operation actually works.

REB provides pallet flow rack design and other customized warehouse storage solutions, with the ability to develop systems around unique product requirements. Contact REB to discuss your expansion goals and to develop a storage solution that supports your inventory, fulfillment processes, and long-term growth strategy.

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