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Double Deep Racking Solution
Akuros helps cold storage, 3PL, food and industrial warehouses improve pallet capacity with double deep racking, matched reach trucks and practical warehouse equipment planning.
Planning Checks Before Layout
- Pallet size, cargo weight and load center
- SKU quantity and pallet quantity per SKU
- Aisle width, lift height and floor condition
- Double deep reach truck or scissors reach truck matching
- Battery, tire and safety equipment configuration
Quick Summary
Double deep racking is a high-density pallet storage solution that stores pallets two positions deep, helping warehouses increase storage capacity compared with standard selective racking. Akuros supports double deep racking projects by matching rack layout, pallet size, cargo weight, aisle width, lift height, double deep reach trucks, batteries, tires and safety equipment into one coordinated warehouse solution.
What Is Double Deep Racking?
Double deep racking is a pallet storage system where pallets are stored two-deep on each side of the aisle. Compared with standard selective pallet racking, it reduces the number of aisles and increases pallet positions within the same warehouse footprint.
This solution is commonly used in cold storage warehouses, third-party logistics centers, food and beverage warehouses, raw material storage and industrial pallet storage operations where storage density is important, but full automation is not required.
Because the second pallet position is deeper inside the rack, double deep racking must be matched with a suitable double deep reach truck or scissors reach truck. The racking layout and forklift selection should be planned together before the project is finalized.
Why Double Deep Racking Is Useful for Space Optimization
Many warehouses lose valuable storage capacity because the aisle layout is based on standard selective racking. Selective racking provides excellent pallet access, but it requires more aisles and uses more floor area for forklift movement.
Double deep racking improves space utilization by reducing aisle quantity and increasing pallet density. For cold storage warehouses, this can be especially valuable because every square meter requires refrigeration cost. For 3PL warehouses, higher pallet density can improve rental value and storage profitability.
Akuros helps customers evaluate whether double deep racking is suitable based on SKU quantity, pallet quantity per SKU, turnover rate, forklift type, aisle width and target pallet positions.
Double Deep Racking Solution Gallery
Use these image positions as temporary Akuros site placeholders. Replace them later with project drawings, warehouse layouts, racking diagrams or real installation photos.
Double deep racking layout
Two-deep pallet storage
Reach truck matching
Aisle width planning
Cold storage pallet capacity
Warehouse workflow review
Best-Fit Applications
Double deep racking is suitable for warehouses that need higher storage density while still keeping practical forklift operation.
冷蔵倉庫
Double deep racking is suitable for warehouses that need higher storage density while still keeping practical forklift operation.
3PL cold chain logistics facilities
Useful for 3PL cold chain logistics facilities where pallet capacity and batch movement need to be planned together.
食品・飲料倉庫
Suitable for food and beverage warehouses that need practical pallet storage with better density than standard selective racking.
Frozen food and raw material storage
Works for frozen food and raw material storage where each SKU has enough pallet quantity to support deeper storage.
Manufacturing warehouses
Supports manufacturing warehouses that need more pallet positions without expanding the building.
Industrial pallet storage
Suitable for industrial pallet storage where storage density and forklift operation must be balanced.
Distribution centers with medium SKU variety
Fits distribution centers with medium SKU variety that need better storage density without full automation.
Warehouses where each SKU has multiple pallets
Best suited for warehouses where each SKU has multiple pallets and does not require 100% direct access to every pallet.
This solution is especially suitable when the warehouse does not require 100% direct access to every pallet but still needs better flexibility than drive-in racking.
ダブル・ディープ・ラックの仕組み
In a double deep racking layout, pallets are stored two positions deep. The first pallet is placed at the front position, and the second pallet is stored behind it. A double deep reach truck uses telescopic or scissor forks to access the rear pallet position.
The system usually provides higher pallet capacity than selective racking while keeping better operating efficiency than some very dense storage systems. However, because the rear pallet is blocked by the front pallet, pallet accessibility is lower than selective racking.
This means double deep racking is best used where each SKU has at least two pallets or where batch storage is acceptable.
Key Advantages of Double Deep Racking
Limitations and When Not to Use Double Deep Racking
Double deep racking is not suitable for every warehouse. It should not be selected only because it increases pallet positions.
This solution may not be ideal if:
- The warehouse has very high SKU variety
- Each SKU usually has only one pallet
- 100% direct pallet access is required
- FIFO is very strict for every pallet position
- The warehouse cannot use a suitable double deep reach truck
- The aisle width or floor condition cannot support the required forklift operation
- Operators need very fast individual pallet picking
In these cases, selective racking, VNA racking or another storage system may be more suitable.
Forklift Matching for Double Deep Racking
Double deep racking requires the right forklift. A normal reach truck may not be able to access the rear pallet position properly. Akuros can help match the rack design with suitable double deep reach trucks or scissors reach trucks.
Important forklift matching factors include:
- Pallet size
- 荷重重量
- Load center
- マストの位置調整
- Rack beam level
- 通路幅
- Fork extension distance
- Residual capacity at height
- Battery capacity
- Tire type
- Cold storage configuration if needed
For cold storage and high-bay double deep applications, residual capacity and stability should be carefully reviewed before finalizing the truck configuration.
Double Deep Racking vs Other Storage Systems
Double Deep vs Selective Racking
Selective racking provides 100% pallet access and maximum flexibility, but storage density is lower. Double deep racking improves pallet capacity, but pallet accessibility is reduced.
Double Deep vs Drive-in Racking
Drive-in racking can provide high-density storage for fewer SKUs, but forklift operation is slower and safety planning is more critical. Double deep racking usually offers better flexibility and easier daily operation.
Double Deep vs Shuttle Racking
Shuttle racking can provide higher density and semi-automated operation, but investment cost is higher and batch management requirements are stricter. Double deep racking is often a more practical intermediate solution.
Double Deep vs VNA Racking
VNA racking reduces aisle width and keeps direct pallet access, but it requires specialized VNA forklifts and higher floor requirements. Double deep racking is easier to apply in many standard warehouse projects.
What Data We Need Before Planning
To evaluate whether double deep racking is suitable for your warehouse, Akuros usually needs the following information:
- Pallet size with cargo
- Maximum and average pallet weight
- Warehouse length, width and clear height
- Target pallet positions
- SKU quantity
- Pallet quantity per SKU
- Daily inbound and outbound frequency
- FIFO or batch storage requirement
- Temperature range
- Existing or preferred forklift type
- Required lift height
- Aisle width limitation
- 床面の状態
- Loading dock and door position
- Future expansion plan
With this data, Akuros can help compare double deep racking with selective, VNA, drive-in and shuttle options.
Why Choose Akuros for Double Deep Racking Solutions
Akuros understands that double deep racking is not only a racking decision. It is a forklift and warehouse workflow decision.
The system must match the right reach truck, aisle width, pallet weight, lift height, battery configuration and operator workflow. Akuros supports customers by reviewing warehouse data, recommending suitable equipment, and helping avoid common mismatches between racking layout and forklift capability.
For cold storage, food, beverage, logistics and industrial warehouse projects, Akuros can help build a practical double deep racking solution that balances storage density, efficiency, safety and investment cost.
Learn more about Akuros
よくあるご質問
These questions and answers match the FAQPage structured data below.
What is double deep racking?
Double deep racking is a pallet racking system where pallets are stored two positions deep. It reduces the number of aisles and increases pallet storage capacity compared with standard selective racking.
Is double deep racking suitable for cold storage warehouses?
Yes. Double deep racking is widely used in cold storage and cold chain logistics because it can increase pallet capacity and reduce wasted aisle space. It should be matched with suitable cold storage forklifts and battery configurations.
What forklift is needed for double deep racking?
Double deep racking usually requires a double deep reach truck or scissors reach truck with telescopic or scissor forks. The forklift must be selected according to pallet weight, lift height, aisle width and required reach distance.
Does double deep racking provide 100% pallet access?
No. Double deep racking does not provide 100% direct access because the rear pallet is blocked by the front pallet. It is best suited for SKUs with multiple pallets or batch storage operations.
How much storage capacity can double deep racking improve?
The exact improvement depends on warehouse dimensions, aisle layout, pallet size and rack height. In many projects, double deep racking can significantly increase pallet positions compared with standard selective racking by reducing aisle quantity.
What information is needed to design double deep racking?
Key information includes pallet size, cargo weight, warehouse clear height, target pallet positions, SKU quantity, pallet quantity per SKU, forklift type, aisle width and storage method.
Is double deep racking better than selective racking?
It depends on the warehouse operation. Selective racking is better for high SKU variety and direct access. Double deep racking is better when higher storage density is needed and each SKU has enough pallet quantity to support two-deep storage.
Can Akuros provide both double deep racking and matching forklifts?
Yes. Akuros can help match double deep racking with suitable double deep reach trucks, batteries, tires, safety equipment and warehouse layout planning.