Push Back Racking

Push back racking systems use a series of nested carts on inclined rails, allowing pallets to be stored up to 6 deep. Wh...

Push Back Racking

Push back racking systems use a series of nested carts on inclined rails, allowing pallets to be stored up to 6 deep. When a pallet is removed, the remaining pallets automatically roll forward. This LIFO system provides excellent density without sacrificing selectivity.

Up to 6 pallets deep
Gravity-fed system
LIFO operation
High density with selectivity

Overview

Push back racking is an innovative high-density storage system that combines the density advantages of drive-in racking with significantly better selectivity. Using a series of nested carts on inclined rails, push back systems allow pallets to be stored up to 6 positions deep from a single aisle, with each position automatically feeding forward when a pallet is removed.

The system operates on a Last-In, First-Out (LIFO) basis. When a new pallet is loaded, it pushes the existing pallets back along the inclined rails. When a pallet is removed from the front, gravity causes all remaining pallets to roll forward to the pick face, ensuring that a pallet is always available at the aisle position.

Push back racking is particularly popular in the UAE's FMCG, beverage, and cold storage sectors, where it provides excellent density for products with moderate SKU counts and consistent pallet sizes. Unlike drive-in racking, push back systems do not require forklifts to enter the racking structure, significantly reducing the risk of structural damage and improving operational safety.

System Operation & Mechanics

Push back racking uses a series of telescoping carts that nest together on inclined rails within the racking structure. The rails are angled at approximately 3-4 degrees from front to back, creating a gentle slope that allows the carts to roll forward under gravity.

When loading the first pallet, it is placed on the front cart. The second pallet pushes the first back along the rails to the second position. The third pallet pushes both previous pallets back, and so on, up to 6 positions deep. Each cart nests partially inside the one behind it, allowing efficient use of the available depth.

When unloading, the forklift removes the front pallet. The remaining pallets immediately and smoothly roll forward on their carts, presenting the next pallet at the aisle face. This automatic feed-forward mechanism eliminates the need for the forklift to enter the racking structure, making push back significantly safer and faster than drive-in racking.

Advantages

Key Benefits

High Density with Safety

Achieve density comparable to drive-in racking without forklifts entering the structure, dramatically reducing collision damage and safety risks.

Automatic Feed-Forward

Gravity-powered cart movement ensures the next pallet is always presented at the pick face, eliminating empty aisle travel.

Multiple SKUs per Lane

Unlike drive-in racking where each lane should hold one SKU, push back lanes can store different SKUs at different depths if needed.

Fast Loading & Unloading

Forklift operators never enter the racking structure, enabling faster cycle times and higher throughput than drive-in systems.

Reduced Racking Damage

Since forklifts only operate from the aisle, the risk of structural damage from forklift impacts is virtually eliminated.

Flexible Depth Options

Systems can be configured from 2 to 6 pallets deep, with different depths on different levels within the same bay.

Industries & Use Cases

FMCG distribution centers
Beverage warehouses and breweries
Cold and frozen storage
Manufacturing finished goods storage
Retail distribution centers
Third-party logistics providers
Pharmaceutical warehouses
Seasonal product storage

Technical Details

Storage Depth2 to 6 pallets deep

Maximum HeightUp to 10,000mm

Pallet WeightUp to 1,500 kg per pallet

Cart TypeNested telescoping steel carts

Rail Incline3° to 4° slope

Aisle WidthStandard forklift aisles

Cart MaterialHeavy-gauge welded steel

Operating Temperature-30°C to +50°C

Operational Efficiency Gains

Push back racking delivers measurable efficiency gains over drive-in racking. Because forklifts never enter the structure, operators can load and unload pallets from the aisle in 30-45 seconds per pallet, compared to 60-90 seconds for drive-in operations. This 40-50% reduction in cycle time translates to higher throughput with fewer forklift operators. In a typical 3,000-pallet facility, switching from drive-in to push back racking can reduce labor costs by 15-20% while simultaneously reducing racking damage repair costs by up to 80%.

Engineering & Cart Design

Our push back carts are manufactured from heavy-gauge welded steel with precision-machined wheel assemblies. Each cart undergoes individual load testing before shipment. The nesting design ensures smooth telescoping action even under full load, and the wheel bearings are sealed and lubricated for maintenance-free operation over thousands of cycles. Rail profiles are rolled from structural steel and feature integral wheel guides that prevent cart derailment.

FAQ

Frequently Asked Questions

There is no theoretical maximum length. Items are supported across multiple arms, so lengths of 6 meters, 12 meters, or even longer can be accommodated by simply adding more columns to the run. We regularly design systems for 12m steel beams and 6m timber planks.

Absolutely. Our push back systems are designed with materials and lubricants rated for continuous operation at temperatures as low as -30°C. The gravity-powered operation means there are no motors or electronics that could be affected by extreme cold.

Push back racking typically costs 20-30% more than drive-in racking per pallet position due to the cart mechanisms. However, the reduced forklift damage, faster cycle times, and improved safety often result in a lower total cost of ownership over the system's lifetime.

Regular inspections should check for damaged uprights, bent rails, loose guide rails, and worn column protectors. We recommend monthly visual inspections by warehouse staff and annual professional structural inspections. Prompt replacement of damaged components is critical for safety in drive-in systems.

Push back racking operates on a LIFO basis—pallets are loaded and retrieved from the same (front) end. Pallet flow racking operates on a FIFO basis—pallets are loaded at one end and retrieved from the other using gravity rollers. Push back is ideal for batch operations, while flow racking suits date-sensitive inventory.

Standard counterbalance forklifts with free-lift masts work well for most drive-in installations. The mast must be able to lift the pallet above the highest rail level before entering the lane. We provide detailed forklift specifications during the design phase.

Yes, our push back systems support pallet weights up to 1,500 kg per position. The cart and rail mechanisms are engineered with appropriate safety factors. Speed controllers regulate the descent rate of loaded carts to prevent dangerous acceleration. All systems comply with FEM safety standards.

Yes, push back racking is commonly installed on both sides of an aisle, creating a highly efficient layout. A single aisle serves lanes on both sides, maximizing the ratio of storage positions to aisle space. This configuration is one of the most space-efficient options available.

Push back racking offers very fast cycle times—typically 30-45 seconds per pallet for loading and retrieval. Since the forklift never enters the racking structure (unlike drive-in systems), there is no time spent navigating narrow lanes. This makes push back one of the fastest high-density storage options.

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Push Back Racking