Why Mezzanines Are Not the Best Alternative to Block Stacking

Mezzanine Alternative

Block stacking may appear to be a cheap and effective storage solution for many companies whether it’s during periods of growth or simply through tradition.

Most people understand that block stacking isn’t always the most effective or efficient way to store pallets but, in many circumstances, it does what is required.

However, that appears to be changing with a growing number of enquiries from companies looking for alternatives to block stacking their pallets.

Some have said they are receiving pressure from the HSE to reduce the number of pallets high they are block stacking.

Some have said that they can no longer run the risk of the products getting damaged by block stacking.

Others are finding the poor space utilisation a problem, coupled with inefficiencies of continually moving stock to access the pallets required.

But whatever the reason, companies are looking at their options – and many see mezzanine floors as the best way to maximise the height in the building.

Mezzanine floors are often seen as the natural alternative to block stacking as they enable customers to maximise the available height and achieve that additional level of storage within the same space.

However, designing and installing a Mezzanine Floor just to create one additional level of storage may not be the most cost-effective approach.

Compromises will need to be made on ground level to accommodate structural columns, issues with accessibility will just increase, and materials handling on the mezzanine floor could present real challenges – all for one additional pallet level?

As with most projects, there is no solution which is right for every single client, however, there are a few solutions we think may provide additional benefits, both in terms of capacity and in operational efficiencies.

Maxi Cube Shuttle Racking

Maxi Cube Shuttle Racking is a semi-automated, high density storage solution, really does Max the Cube, delivering superior space utilisation that can often double or even treble the storage capacity in a warehouse. However, it is the enormous operational benefits that it offers, including a reduction in travel times, improving picking times and reducing the number of forklift trucks required to achieve the desired throughputs of stock.

Capable of storing pallets in blocks of over 100 pallets deep (although 40-50 is more practical) and up to 40 feet high, with semi-automated shuttles which enter the racking to move pallets into position, our Maxi Cube Shuttle Racking is changing the way many companies are thinking about their warehouse.

Click here to see how one company achieved a 242% increase in capacity from switching from block stacking to our Maxi Cube Shuttle Racking

Shuttle Racking

Maxi Cube Push Back Racking

Maxi Cube Push Back Racking is a high-density dynamic racking which uses carts and gravitational forces to store pallets in blocks of up to 6-deep. The number of pallets high is often determined by the specification of the forklift truck, however, most should be capable of achieving 4 pallets high to maximise the available height in the building.

Our Maxi Cube Push Back Racking also offers the additional flexibility of being able to store different types of pallets in the same system, including Euro Pallets, CHEP pallets as well as IBCs.

Dynamic Pallet Racking

Maxi Cube Drive-In Racking

Maxi Cube Drive-In Racking has traditionally been popular in industries such as the food and drink sector and has the capability to create high density blocks of pallet storage. However, unlike push back racking and shuttle racking, each pallet must be moved manually into position with the forklift entering the racking system.

Whilst a cheaper alternative to push back racking and shuttle racking, the major challenges associated with drive-in racking are space utilisation, speed of accessibility and damage to racking.

Drivein Racking Scotland

To find out more contact Thistle Systems Shuttle Racking Design team – click here or phone us on 01236 453 888