What is Pushback Pallet Racking?
Pushback pallet racking engineered by StahlRack Intralogistics GmbH is an advanced high-density dynamic storage system operating on the Last-In, First-Out (LIFO) inventory principle. Pallets are supported on telescoping nested carts that glide smoothly along inclined structural steel rails.
When loading, incoming pallets gently push existing pallets deeper into the storage lane (ranging from 2 to 6 pallets deep). Upon retrieval, gravity automatically moves the remaining pallets forward to the picking face, ensuring rapid access from a single operating aisle.
- 100% SKU selectivity per lane: Every lane can hold a distinct product line for efficient inventory control.
- No forklift lane entry: Forklifts remain in the central aisle, drastically lowering rack frame impact damage and improving worker safety.
- Reduced travel cycles: Single-aisle handling accelerates loading and retrieval throughput for busy logistics hubs.
Key System Components & Technical Specifications
StahlRack Intralogistics GmbH designs and manufactures every pushback system according to European FEM 10.2.02 and DIN EN 15512 structural standards, ensuring long-term stability and operational safety.
Nested Wheeled Carts
Telescoping heavy-duty steel carts equipped with precision sealed bearings for smooth, jam-free travel under full payloads.
Inclined Guide Rails
Heavy-gage structural channels sloped at a precise angle to ensure reliable gravity flow without excessive impact speeds.
Structural Frames & Beams
High-tensile steel uprights engineered for heavy vertical loads and dynamic operational stresses.
Safety End Stops
Integrated front impact stops and rear buffers absorb kinetic force during pallet retrieval and prevent dislodgement.
| Parameter | Specification Standard | Customisation Options |
|---|---|---|
| Storage Depth | 2, 3, 4, 5, or 6 pallets deep per lane | Tailored to warehouse column grid & hall depth |
| Load Capacity | Up to 1,500 kg per pallet position | Heavy-duty structural profiles for high unit loads |
| Pallet Standard Compatibility | EPAL Euro pallets (1200x800mm), Industrial (1200x1000mm) | Custom sizes, plastic pallets, and wooden skids |
| Operating Temperature | Ambient indoor logistics down to -30°C freezer stores | Cold-resistant lubricants, stainless bearings & hot-dip galvanising |
| Design Compliance | DIN EN 15512, DIN EN 15620, FEM 10.2.02, ISO 9001 | AS4084 / ANSI RMI standards for export projects |
Safe Loading & Unloading Procedures
Proper operator handling ensures smooth pallet flow and protects inventory. Under DIN EN 15635 guidelines, following structured loading steps minimizes equipment wear.
Correct Loading Steps
1. Placing the First Pallet: Align the pallet over the top nested cart, lower it gently onto the cart surface, and verify centering before releasing.
2. Loading Subsequent Pallets: Position the second pallet at the picking face and gently push the first pallet back into the lane to reveal the next cart layer. Repeat for remaining depths.
Correct Unloading Steps
1. Retrieval Control: Lift the front pallet clear of the stop plate and back away slowly. The inclined rail design allow subsequent pallets to slide forward in a controlled glide.
2. Speed Management: Maintain a steady backward speed with the forklift to control the forward progression of remaining pallets.
Pushback Racking vs. Alternative High-Density Systems
Compare dynamic racking technologies to select the ideal balance of storage density, selectivity, and operational throughput for your warehouse.
| Feature / System | Pushback Pallet Racking | Pallet Live / Gravity Flow | Radio Shuttle Racking |
|---|---|---|---|
| Inventory Rotation | LIFO (Last-In, First-Out) | FIFO (First-In, First-Out) | FIFO or LIFO |
| Storage Density | High (2–6 pallets deep) | Very High (Up to 15+ deep) | Ultra High (Up to 30+ deep) |
| Aisle Requirement | Single loading/unloading aisle | Dedicated entry & exit aisles | Single or double aisles |
| SKU Selectivity | 100% per lane level | 100% per lane level | 100% per lane level |
| Maintenance & Power | Zero power, purely gravity-assisted | Zero power, braking rollers required | Requires battery-powered shuttle vehicles |
| Initial Investment | Moderate & highly cost-effective | Higher due to roller beds | Higher due to automation electronics |
Ideal Applications for Pushback Systems
Pushback racking by StahlRack Intralogistics GmbH is widely deployed in high-volume industries requiring space optimization and fast handling:
- Cold Storage & Freezers: High storage density reduces refrigerated air volume losses and operating power costs.
- Food & Beverage Distribution: Efficient handling of batch-manufactured goods with medium-term shelf life.
- Pharmaceuticals & Chemicals: High-density storage of bulk raw materials and finished goods in strict ambient conditions.
- Buffer Storage Areas: Fast staging zones adjacent to shipping docks and manufacturing output lines.
Why Source From StahlRack Intralogistics GmbH?
With decades of experience in structural racking manufacturing, StahlRack provides end-to-end engineering support for global logistics buyers.
- Free CAD & 3D Layouts: Delivered within 24 hours based on your hall dimensions.
- ISO 9001 Certified Quality: Batch traceability on all steel beams and uprights.
- Turnkey Export Services: Professional packaging, container loading, and on-site assembly guidance worldwide.
Questions Engineers & Procurement Teams Ask
StahlRack pushback racking is engineered for heavy-duty industrial loads. Each pallet position typically supports between 750 kg and 1,500 kg depending on the beam profile, frame structural specification, and wheel assembly choices.
Pushback racking configurations standardly range from 2 to 6 pallets deep per lane. The optimal depth is selected based on your SKU volume, available hall depth, and forklift reach capacity.
No specialized forklifts are needed. Standard counterbalanced forklifts, reach trucks, and articulated forklifts can all operate pushback racking systems, provided they meet the required lift height and payload capacity.
Yes. Pushback racking is ideal for cold storage because high-density storage minimizes cold air volume losses. StahlRack manufactures low-temperature stainless steel bearings and specialized coatings rated for freezing conditions down to -30°C.
Pushback racking uses Last-In, First-Out (LIFO) inventory flow. When loading, the forklift gently pushes existing pallets back using the incoming pallet. When unloading, gravity smoothly glides subsequent pallets forward to the picking face.
Plan Your Pushback Racking System Today
Send your warehouse floor plan, pallet dimensions, and unit load specifications to [email protected]. Our engineering team will deliver a customized CAD layout and structural quotation within 24 hours.