The Essential Role of Storage Racks in Logistics Warehouse Management

Designed to organise and store products in storage areas, storage racks are a crucial component in the efficient management of logistics warehouses. Various types of racking systems exist, each designed to streamline logistics operations and stock management. Hugo Mascret, Methods Engineer responsible for the commissioning of racks at Exotec, provides an insightful overview. .

The emergence of ‘industrial’ storage racks dates back to the 1960s, a period marked by rapid industrialisation and the rise of consumer society. The expansion of mass retailing, mail order, and the automotive industry fostered the development of modern logistics, alongside the construction of large retail outlets and warehouses. These infrastructures were meticulously organised, from receiving and storage to preparation and dispatch, optimising the management of ever-increasing flows of goods.

The introduction of multi-storey systems marked a significant advancement in material handling. These installations, consisting of numerous horizontal storage levels fixed to vertical supports, were developed. Equipped with walkways stacked one above the other, they allowed for high-density storage up to 5 to 8 metres. Their primary advantage lies in freeing up floor space, maximising the use of available height in warehouses. By increasing storage density and reducing the need for long daily walks within the warehouse, these racks quickly became indispensable in stock management.

In the 2000s, automated storage racks transformed warehouse management. Designed to increase storage density while reducing manual labour for operators, these racks make it possible to utilise even greater vertical space. “Traditional installations typically reached just 6 metres in height, whereas robotic storage racks can easily exceed 10 metres, with significantly more containers for holding goods,” explains Hugo Mascret.

These systems allow for the storage of a far larger quantity of products within the same floor area. They are adaptable to various types of goods… and thus applicable across a wide range of industries, including pharmaceuticals, e-commerce, and the automotive sector !

The benefits extend beyond density, as automated racks facilitate narrower aisles, thanks to robotised material handling.
With increased storage density and the accommodation of more heterogeneous products, automated systems not only improve ergonomics and safety for operators—using robots such as Exotec’s AMR Skypod—but also enhance operational efficiency in potentially high-risk environments.

The smaller footprint of high-density storage racks offers significant economic advantages. “Warehouses can be more compact, leading to savings in property acquisition or rental costs, as well as in related expenses like fire safety,” notes Hugo Mascret.

Additionally, with the increased density of storage, the need for larger warehousing spaces is eliminated. As a result, businesses can opt for local warehouses instead of large logistics hubs, further reducing their environmental impact. These automated solutions can be tailored to meet the needs of various sectors: “For instance, pharmacies can use robotic systems to manage substantial stocks of pharmaceuticals.” ’

Optimising logistics by increasing the density of storage racks requires compliance with current regulations governing construction and safety standards. “Storage structures fall under the Labour Code and the safety standards applicable to metal shelving systems,” explains Mascret.

• Several regulations must be adhered to, including:
  NF EN 15 512: governs the design, structural integrity, and mechanical strength requirements for storage racks.
• Seismic Zone Regulations: additional rules apply to rack calculations, with site-specific considerations impacting structural compliance. To streamline design and reduce costs, Exotec offers various levels of standard reinforcement, tailored to the region where the racking systems will be installed.
• Fire Safety Regulations: overseen by FM Global, these may require the installation of sprinkler systems (automatic water extinguishing devices) within warehouses and even within the racks themselves.

“Our designers are experts in racking systems,” concludes Hugo Mascret. “They are well-versed in the regulations and stay up to date with new standards.” Modern racks, therefore, offer numerous opportunities for optimising warehouse space by enabling overhead storage and maximising storage density. Expert companies like Exotec are available to design your project in accordance with these requirements, boosting productivity and efficiency.

The Performance of an Automotive Parts Warehousing Project by Exotec

• Location: United Kingdom
• A total of 255,000 rack spaces, using two systems, each with 127,500 cells.

Rack height: up to 12 metres.