Choosing the Right Racking Layout for Your Warehouse

Designing an efficient warehouse layout is vital for optimising operations & making the most of available space

The layout of your racking system plays a key role in this process, influencing everything from accessibility to safety. Here are some essential tips for designing a warehouse layout that aligns with optimal aisle widths and load capacities.

Understand Your Requirements

Before mapping out your layout, assess the types and volumes of items you’ll be storing. This will inform your choice of racking system — whether Pallet Racking, Cantilever, or Mezzanine — and help determine the appropriate load capacity and aisle widths.

Optimal Aisle Width

Aisle width will depend on the type of forklifts or materials handling equipment used, as well as the frequency of access required. Standard aisles generally range from 3.5 to 4.5 metres, allowing for the safe and efficient operation of conventional forklifts. If you’re using more compact or specialised equipment, such as reach or turret trucks, narrower aisles may be appropriate, allowing you to maximise storage space.

Maximising Load Capacity

Ensure that your racking’s load capacity matches the heaviest items you intend to store. Always follow the manufacturer’s guidelines to avoid overloading, which can compromise structural integrity and create safety risks. Regularly review load capacities as your inventory changes to ensure ongoing compliance and safety.

Layout Flexibility

Design your layout to be adaptable enough to accommodate future changes or expansion. Our modular racking systems can be easily reconfigured as your storage needs evolve. If growth is anticipated, consider leaving space for additional racking units.

Safety & Accessibility

Safety must be a priority in your warehouse layout. Provide sufficient space for the safe movement of goods and ensure that emergency exits remain unobstructed. Implement safety measures such as adequate lighting, clear signage, and floor markings to guide the safe navigation of staff and machinery.

Streamlining Operations

Position racking to support efficient workflows. Locate high-turnover items near packing and dispatch areas to minimise travel time. Explore various racking configurations — such as double-deep, drive-in, or push-back systems — to boost storage density without compromising accessibility, depending on your stock rotation.

Seek Professional Advice

Engaging with warehouse design specialists can offer valuable insights and help you avoid costly mistakes. Companies like Emrack provide tailored advice to ensure your racking layout not only maximises space but also enhances operational efficiency.

By carefully planning your warehouse layout and considering these key factors, you can create a space that is both efficient and safe. A well-designed racking system not only improves productivity but also evolves with your business, supporting long-term operational success.