Pallets for Warehousing: How to Maximize Your Storage Efficiency

Your warehouse racking system is only as efficient as the pallets that go into it. Choosing the wrong pallet type, grade, or size creates wasted space, safety risks, and operational bottlenecks that compound every day.

Pallet-Racking Compatibility: The Non-Negotiable

Before ordering any pallets for warehouse use, verify compatibility with your racking system. Selective racking (the most common type) is designed around specific pallet dimensions and weight ratings. Using pallets that overhang excessively, underspan beam sets, or exceed weight limits creates a genuine collapse risk. Always cross-reference your racking manufacturer's specifications with your pallet supplier.

Pallet Height and Frame Clearance

Warehouse racking is set at specific beam heights based on pallet height plus load height plus clearance. If you switch from stringer pallets (typically 5.5" tall) to block pallets (typically 6–6.5" tall) without adjusting beam heights, you lose load height per level — meaning less product per rack position. Even a 1" pallet height change across thousands of rack positions meaningfully reduces your storage density.

Choosing Between Stringer and Block Pallets for Your Racking

For selective racking with standard two-way forklift entry, stringer pallets work perfectly and cost less than block pallets. For operations with reach trucks or automated storage and retrieval systems (AS/RS) that require four-way entry from any direction, block pallets are essential. Consult your racking and materials handling equipment supplier before standardizing on a pallet type.

Managing Empty Pallet Storage

Empty pallets in a warehouse represent a real space and safety issue if not managed properly. Dedicated horizontal pallet storage bays, vertical pallet racks, or outdoor pallet cages keep empty pallets organized and out of high-traffic forklift lanes. Serv-U-Pallets Inc. can calibrate delivery frequency to match your throughput so you never have excessive empty pallet inventory taking up valuable floor space.

High-Density Storage Environments

Push-back racking, drive-in racking, and pallet flow racking systems all place additional structural demands on pallets — the pallet must slide, roll, or stack within tight dimensional tolerances. These environments typically require Grade 1 or new pallets with consistent dimensions and no protrusions. Consult with us before specifying pallets for high-density storage installations at your Ontario facility.