There is no single rack system that works for every warehouse. The right choice depends on what you are storing, how you access it, how much floor space you have, and what your forklift fleet looks like. Picking the wrong rack type wastes money and floor space. Picking the right one can increase your storage density by 30% to 60% without adding a single square foot to your building.
Here is a straightforward comparison of the five most common pallet rack systems we install in Las Vegas warehouses, and when each one makes sense.
Selective Pallet Rack: The Default for a Reason
Selective rack is the most common system in warehouses across the country, and for good reason. Every pallet is directly accessible from the aisle. You do not have to move one pallet to get to another.
- Best for: Warehouses with a high number of SKUs and low pallets per SKU. Distribution centers, third-party logistics, retail fulfillment.
- Access: 100% selectivity. Every pallet is reachable from the aisle.
- Density: Lowest density of all rack types because aisles take up roughly 50% of floor space.
- Cost: Lowest cost per pallet position. $50 to $100 new per position.
- Forklift type: Works with any forklift type including reach trucks for narrow aisles.
Drive-In Rack: Maximum Density, Limited Access
Drive-in rack eliminates aisles between rows. The forklift drives directly into the rack structure to place and retrieve pallets. This increases storage density significantly, but you lose selectivity.
- Best for: High volume of the same SKU. Cold storage, beverage, food manufacturing, seasonal inventory.
- Access: Last in, first out (LIFO). You can only access the pallet at the front of each lane.
- Density: 75% to 85% more storage than selective rack in the same footprint.
- Cost: $80 to $150 per pallet position. More steel per position because of the rail structure.
- Forklift type: Requires a counterbalanced forklift. Reach trucks do not work in drive-in systems.
Push-Back Rack: Density with Better Selectivity
Push-back rack stores pallets on nested carts that ride on inclined rails. When you place a new pallet, it pushes the one behind it back. When you remove the front pallet, the ones behind it roll forward. You get multiple pallets deep without driving into the rack.
- Best for: Medium SKU count with 2 to 6 pallets deep per SKU. Food distribution, beverage, manufacturing.
- Access: LIFO, but from the aisle face. No need to drive into the structure.
- Density: 40% to 60% more storage than selective rack.
- Cost: $120 to $200 per pallet position. The cart and rail system adds cost.
- Forklift type: Standard counterbalanced or reach truck from the aisle.
Cantilever Rack: For Long, Awkward, and Oversized Items
Cantilever rack has no front columns. Arms extend from a single column, creating unobstructed storage for long items like lumber, pipe, bar stock, sheet goods, and furniture.
- Best for: Building materials, lumber yards, metal service centers, furniture warehouses, plumbing supply.
- Access: Full access to every arm level from the front.
- Density: Moderate. Depends on arm length and spacing.
- Cost: $100 to $200+ per arm level depending on capacity and height.
- Forklift type: Standard counterbalanced with long forks or side-loader for narrow aisles.
Pallet Flow Rack: First In, First Out Automation
Pallet flow rack uses gravity rollers set on a slight incline. Pallets are loaded from the back and roll forward to the pick face. This gives you first-in, first-out (FIFO) rotation automatically, which matters for perishable or date-sensitive inventory.
- Best for: Food and beverage, pharmaceuticals, any product with expiration dates or lot tracking.
- Access: FIFO. The oldest pallet is always at the pick face.
- Density: High. Multiple pallets deep with separate load and pick aisles.
- Cost: $200 to $400+ per pallet position. The roller and brake system is the most expensive component.
- Forklift type: Standard forklift from both load and pick aisles.
How to Decide: Three Questions That Narrow It Down
You do not need to be a warehouse engineer to make a good decision. Start with these three questions:
- How many different products do you store? High SKU count points to selective. Low SKU count with high volume points to drive-in or push-back.
- Does product rotation matter? If you need FIFO (expiration dates, lot control), pallet flow is the answer. If LIFO is acceptable, drive-in and push-back are options.
- What does your forklift fleet look like? Drive-in requires counterbalanced forklifts. Narrow-aisle selective works with reach trucks. Your existing equipment can steer the decision.
Most Warehouses Use More Than One Type
The majority of the larger warehouse layouts we design in Las Vegas use a combination of rack types. Selective rack for high-pick SKUs near the shipping dock. Drive-in or push-back for bulk storage in the back. Cantilever along a side wall for oversized items.
We survey your warehouse, review your inventory profile, and recommend the layout that maximizes your storage density within your budget. No charge for the initial consultation and layout recommendation.
Call us at (702) 734-8848 or fill out the form below. We will walk through your options and give you a layout that makes sense for how your operation actually works.