Drive-In pallet racking for high-density storage

What is Drive-In pallet racking

Drive-in pallet racking (and its drive-through variant) is a high-density pallet storage system that enables deep-lane storage within aisles (tunnels) formed inside the racking structure. By reducing working aisles compared to selective pallet racking, the system maximizes the use of available warehouse volume (floor area and height) and delivers the greatest value when handling large quantities per SKU, with homogeneous products and low to medium turnover (it is therefore not designed to provide maximum selectivity across many SKUs). In a drive-in configuration, access is from one side only and the typical handling logic is LIFO (Last In – First Out), with loading and unloading from the same face. In a drive-through configuration, lanes are through-passage: pallets are loaded from one side and retrieved from the other, enabling FIFO (First In – First Out)—useful when stock rotation is a constraint (e.g., dated products); to apply FIFO correctly, two operating faces are required (separate loading and unloading areas) along with disciplined flow management. Pallets are handled by placing and retrieving them on dedicated rail supports at each level; the system can be further upgraded by integrating radio-controlled shuttles (Pallet Shuttle), reducing forklift entry into the lanes and improving both efficiency and operational safety.

Benefits of Drive-In racking

Maximized space utilization (floor area and height)

• reduced service aisles and increased storage lanes
• better cube utilization, including in height

Increased storage capacity

• higher density compared to selective layouts
• particularly effective for high stock volumes per single SKU

Cost-effective and straightforward system

• robust, modular, scalable structure
• excellent balance between investment and achievable density
• can be upgraded over time with accessories, protections and evolution options (e.g., Pallet Shuttle)

Typical high-value applications

• environments where “empty” volume is costly (e.g., cold stores and temperature-controlled areas)
• warehouses where picking does not require direct access to every pallet, but operates with accumulation logics

Structure, components and accessories

Load-bearing structure

• steel frames and uprights with bracing for load capacity and stability
• engineered based on: system height, pallet loads, lane depth, operating conditions and handling intensity

Rails and pallet supports

• functional components that define the levels and enable deep-lane storage
• directly affect:
  • pallet support stability
  • smooth forklift manoeuvring within the tunnel
  • reduced damage (pallets and racking)
  • long-term durability and operational continuity

Recommended accessories and protections (best practice)

• anti-impact protections for uprights and critical points
• centring/guide elements and spacers
• signage plus inspection/control criteria to maintain performance and safety throughout the system lifecycle