Pallet Storage Systems: The Complete Guide for Irish Businesses

What Is a Pallet Storage System?

A pallet storage system is a structured arrangement for storing palletised goods in a defined space. The system determines how pallets are accessed (FIFO, LIFO, or random), how densely they can be stored, and how efficiently warehouse operatives can pick and move stock.

Pallet storage systems (supply chain and logistics) range from no-infrastructure approaches, such as floor stacking, to high-capital automated solutions, such as automated storage and retrieval systems (ASRS). Most Irish warehouses use a combination of selective pallet racking and floor stacking.

Types of Pallet Storage Systems

1. Selective Pallet Racking
The most common pallet storage system. Each pallet is stored individually on a beam level and is directly accessible by forklift from the aisle. Suited to warehouses with many SKUs and frequent picking requirements.

2. Double-Deep Racking
Pallets are stored two deep in each lane, halving the number of aisles needed and increasing density. Requires a reach truck with double-deep capability. Access to rear pallets requires moving the front pallet first.

• Higher density than selective racking, suits products with multiple pallets per SKU
• Requires a double-deep reach truck; capital cost is higher than standard forklifts
• Last-in, first-out (LIFO) access pattern, not suitable for FIFO products

3. Drive-In / Drive-Through Racking
The forklift drives into the racking lane itself to deposit or retrieve pallets. Drive-in is LIFO; drive-through allows FIFO. Very high density, suited to bulk storage of a small number of SKUs.

• Extremely high storage density, with minimal aisle space
• Drive-in means LIFO (last in, first out); drive-through means FIFO
• Not suited to high-SKU environments, since pallets behind are inaccessible without clearing the row
• Suited to cold stores, seasonal bulk storage, and single-product warehouses

4. Pallet Live / Gravity Flow Racking
Pallets are loaded at the rear on inclined roller lanes and flow forward by gravity to the picking face. First-in, first-out (FIFO) is automatic. Ideal for high-throughput, date-sensitive products.

• Automatic FIFO, with no manual rotation required
• High throughput at the picking face
• Higher capital cost, due to roller lanes and inclined frames
• Suited to FMCG, food, and beverage distribution with high-turnover SKUs

5. Floor Block Stacking
Pallets are stacked directly on the warehouse floor, typically 2 to 4 high. No racking infrastructure required. Low capital cost, but low density and poor access once pallets are stacked behind others.

6. Mezzanine Pallet Storage
A raised structural floor built within the warehouse to create additional storage levels. Pallets can be accessed by forklift ramp or lift. Suitable for businesses that have run out of ground-floor space without wanting to move premises.

7. Automated Pallet Storage (ASRS)
Fully automated storage and retrieval systems that use cranes or robotics to store and retrieve pallets without human intervention. High capital cost, suited to large-volume operations with repeatable SKU profiles.

Choosing the Right System

• SKU count and pick frequency High SKU count and frequent picking favour selective racking; low SKU count and bulk volume favour drive-in or floor stacking.
• Rotation requirements Date-sensitive or perishable products need FIFO systems, such as selective racking with lane discipline or gravity flow racking.
• Available space and budget Density-focused systems, such as double-deep or drive-in racking, reduce aisle space but raise equipment and handling costs.
• Scale and volume stability Stable, high-volume operations can justify capital investment; variable or growing volumes are often better served by an outsourced facility.

Get a Pallet Storage Quote

Pallet Storage System Comparison: At a Glance

Own Racking vs Outsourced Pallet Storage: Which Is Right for You?

Owning and operating your own pallet storage system makes sense once you have stable volumes, permanent premises, and the capital to invest in racking, forklifts, and staff. Below that threshold, outsourcing pallet storage to a managed 3PL facility is typically more cost-effective and flexible.

Joe McGovern Transport: Managed Pallet Storage in Ireland

At Joe McGovern Transport's Co. Cavan facility, pallets are stored in a combination of selective racking and floor-stacked block configurations across 100,000 sq ft. Our indoor electric forklifts allow handling of both racked and floor-stacked pallets without exhaust contamination.

Clients access their stock information in real time via our online client portal. Outbound distribution is integrated with the Palletxpress Network for 32-county next-day delivery.

• Selective racking and block floor stacking, covering racked and ground-level pallets
• Indoor electric forklifts for clean, food-safe handling
• Real-time stock visibility via bespoke client portal
• Container devanning: 20 ft and 40 ft containers stripped and palletised on-site
• Outbound integrated with Palletxpress 32-county overnight delivery

Frequently Asked Questions

• What is the most common pallet storage system?

  Selective pallet racking is the most common system used in Irish warehouses. It gives 100% direct access to every pallet and suits businesses with a wide range of SKUs and frequent picking needs.
• Which pallet storage system is best for FIFO stock rotation?

  Selective racking with correct lane discipline supports FIFO, and pallet live or gravity flow racking automates FIFO entirely, since pallets flow forward to the picking face by gravity. Both suit date-sensitive or perishable products.
• At what volume does it make sense to own a pallet storage system?

  Owning your own system typically becomes cost-effective at around 200 or more pallets per week, once volumes are stable and you have permanent premises. Below that threshold, outsourcing to a managed 3PL facility is usually more flexible and cost-effective.
• What system does Joe McGovern Transport use for pallet storage?

  Our Co. Cavan facility uses a combination of selective racking and floor block stacking across 100,000 sq ft, handled with indoor electric forklifts and tracked through a real-time online client portal.
• Is outsourced pallet storage cheaper than building my own racking system?

  For most businesses below roughly 200 pallets per week, yes. Outsourced storage avoids capital spend on racking, forklifts, and premises, and is typically profitable from week one, whereas an owned system carries high upfront capital and ongoing management overhead.