Heavy-Duty Pallet Racking Procurement for a Raw Materials Warehouse

Project Overview

Client: A leading modified plastics manufacturer in East China.

Pain Points: The storage of raw materials (PP/ABS granules) and finished products (FIBC/Ton bags, weighing 800–1,200 kg) relied on crude cement blocks. This led to chaotic stacking, mixed batches causing traceability issues, bottom-layer product deformation (over 3% loss rate), and high risks of collapse during manual handling.

 Core Requirements

• Load Capacity: Support ton bags (1.2T) and heavy pallets; unit rack load ≥ 4T.

• Batch Management: Enable "one-pallet-one-code" tracking and FIFO (First-In-First-Out) protocols.

• Environmental Adaptability: Withstand minor floor unevenness and vibrations from frequent forklift operations.

 Proposed Solution

Implementation of a Heavy-Duty Selective Pallet Racking System with specialized accessories:

• Structural Reinforcement: Utilized heavy-duty 90×70mm columns (2.3mm thickness) and reinforced "C-beams" for cross beams. Configured with 4 levels (6m height) supporting 1,500 kg per level.

• Anti-Damage Design: Installed 3mm thick non-slip steel decking panels on each level to prevent ton bag slippage and packaging rupture.

• Precision Positioning: Added column guards and guide rails to minimize impact damage from forklifts.

• Optimized Layout: 8 rows × 40 columns with a 3.5m main aisle, providing 1,280 pallet positions zoned by batch number.

Implementation Results

• Reduced Loss: Eliminated bottom-layer compression deformation; raw material loss rate dropped to <0.5%.

• Efficiency Gains: Inbound/outbound efficiency increased by 90%, inventory counting time reduced by 60%, and batch traceability achieved 100% accuracy.

• Safety & Compliance: Passed 110% static load testing and complied with the Code for Design of Industrial Steel Storage Racking (GB/T 30675–2014).

 Project Highlights

Tailored for the "heavy, bulky, and multi-batch" nature of the materials industry, the solution prioritized reinforced structures and anti-slip decking over standard racking. Although the initial cost increased by 15%, it prevented raw material waste (saving approx. ¥400k annually), resulting in an ROI of just 1.5 years.