Double Deep Pallet Racking – High Efficiency Storage by Bari Engineering

Introduction to Double Deep Pallet Racking

In the competitive logistics and warehousing industry, optimizing every square foot is crucial. If your operation needs more storage without expanding your warehouse footprint, double deep pallet racking is the smart solution. Bari Engineering, a top-tier storage systems manufacturer in Pakistan, offers a high efficiency double deep pallet racking solution that helps businesses scale operations with minimal structural changes.

Let’s dive into how this system works and why it could be the best choice for your warehouse.

What is Double Deep Pallet Racking?

Double deep pallet racking is an advanced version of selective racking where pallets are stored two-deep instead of one. It involves placing two rows of racks back-to-back, which requires a specialized reach truck or deep reach forklift to access the second pallet.

This system provides a balance between increased storage density and reasonable accessibility — making it ideal for businesses with medium-turnover inventory and batch handling.

How the Double Deep Pallet Racking System Works

Racking Design

The design consists of back-to-back frames supporting two pallet positions in depth, accessible from the same aisle. This structure reduces the number of aisles needed, increasing storage capacity.

Special Equipment

To access the inner pallet, forklifts must be equipped with telescopic forks or deep-reach attachments. These allow operators to place or retrieve pallets stored at the back of each row safely.

Inventory Rotation Type

Double deep systems operate on the Last In, First Out (LIFO) method. This makes them suitable for non-perishable goods or SKUs with longer shelf lives.

Benefits of High Efficiency Double Deep Pallet Racking

1. Maximized Storage Density

By reducing aisle space and doubling the depth of storage rows, you can increase pallet positions by up to 30-40% compared to conventional selective racks.

2. Cost-Effective Space Optimization

Instead of expanding your warehouse area, double deep pallet racks utilize existing vertical and horizontal space more efficiently, lowering capital expenditure.

3. Fast and Easy Loading

With the right equipment, pallet placement and retrieval are smooth and time-saving. This increases operational throughput and reduces labor costs.

4. Adaptable to Various Pallet Sizes

Bari Engineering’s systems are fully customizable to fit standard or non-standard pallet sizes, as well as varying weight requirements.

5. Improved Warehouse Organization

Double deep pallet racking is ideal for grouping similar products. It creates clean zones in your warehouse, which improves workflow and reduces search time.

When to Choose Double Deep Pallet Racking

Medium to High Inventory Turnover

If you manage medium to high quantities of similar SKUs and don’t require frequent access to every pallet, this system provides the perfect balance.

Limited Aisle Space

Warehouses with limited aisle space or needing denser storage can benefit from the compact arrangement of a double deep pallet racking system.

Cold and Dry Storage

Whether you are storing pharmaceuticals, packaged goods, or food items with stable shelf lives, this racking system ensures maximum capacity in temperature-controlled environments.

Key Features of Bari Engineering’s Double Deep Racks

Heavy-Duty Construction

We manufacture racks using premium-grade, powder-coated steel to support heavy pallet loads and withstand warehouse wear and tear.

Customizable Dimensions

We offer adjustable beam levels, various height configurations, and custom load capacities to suit your storage needs.

Easy Compatibility with Forklift Systems

Our double deep racks are designed to work seamlessly with reach trucks, deep-reach trucks, and telescopic forklifts.

Safety Accessories

We include pallet support bars, safety pins, upright protectors, and row spacers for increased safety and structural integrity.

Installation & Support by Bari Engineering

Site Survey & Design

Our engineers begin with a comprehensive assessment of your warehouse layout, load profiles, and inventory flow to design the most efficient system.

Fabrication & Installation

All racking components are manufactured in-house using precision machinery and are installed by our trained technicians.

Ongoing Maintenance

We offer regular inspections and support services to keep your double deep pallet racking system operating at peak performance.

Applications of Double Deep Pallet Racking

Logistics & Distribution Centers

Perfect for distribution warehouses handling bulk SKUs with medium access frequency.

Manufacturing Units

Stores raw materials and finished goods with clear segregation and efficient retrieval.

Retail Warehouses

Large retail chains can use this system to organize inventory by category while maximizing floor usage.

Automotive & Spare Parts

The system is ideal for storing bulk components or boxed items, especially those grouped by production batches.

Why Choose Bari Engineering?

At Bari Engineering, we combine modern engineering with industry expertise to deliver durable and efficient storage solutions across Pakistan.

✅ Over a decade of manufacturing experience
✅ ISO-compliant materials and processes
✅ Customization for industrial-scale warehouses
✅ Professional design and installation services
✅ Reliable after-sales support

Frequently Asked Questions (FAQs)

Q1: What forklift is needed for a double deep pallet racking system?

A: A deep-reach truck or a forklift with telescopic forks is required to access the second pallet in a double-deep arrangement.

Q2: What is the maximum height for double deep racks?

A: Racks can go up to 10 meters or more, depending on warehouse height and forklift reach. Custom heights are available on request.

Q3: Can I store different pallet sizes?

A: Yes. Bari Engineering customizes beam widths and depth based on the pallet sizes you use — standard or non-standard.

Q4: Is double deep racking suitable for FIFO operations?

A: No. This system works on a LIFO (Last In, First Out) principle and is not ideal for time-sensitive inventory.

Q5: How long does installation take?

A: Installation time depends on project size, but typically ranges from 3 to 7 working days, including inspection and testing.

Conclusion: A Smarter Way to Store More

With rising real estate and storage costs, businesses can’t afford to waste space. Bari Engineering’s high efficiency double deep pallet racking system offers a powerful solution to increase storage capacity, reduce operational costs, and maintain an organized warehouse.

If you’re ready to upgrade your storage strategy, contact Bari Engineering today for a free consultation and layout design. Our team is ready to help you implement a racking system that delivers long-term performance and value.