DEMAND
Plan for the peak, not one snapshot
Separate average inventory, peak inventory, replenishment needs and expected growth so the target reflects the operation.
WAREHOUSE PALLET CAPACITY PLANNING
Running Out of Pallet Positions?
Running out of pallet positions does not automatically mean you need another building or more of the same rack. Two3 looks at the loads, layout, lift equipment, access needs and growth before comparing the ways to create usable capacity.
- PALLET AND LOAD PROFILE
- LAYOUT OPTIONS
- DENSITY COMPARISONS
- INSTALLATION PLANNING
PALLET CAPACITY DEPENDS ON MORE THAN RACK COUNT
CAPACITY CHECK
4 constraints shape the real pallet count
A pallet-position target only becomes useful when it is tested against the loads, access needs and building. That review tells us whether the answer is reconfiguration, higher-density storage, another system or more space.
LOADS
Design around the actual pallets
Dimensions, overhang, height, weight and pallet condition affect bay spacing, clearances and the systems that can be considered.
ACCESS
Protect the selectivity the team needs
SKU variety, rotation, lot control and pick frequency determine how much density is practical.
BUILDING
Use the space that is really available
Clear height, columns, docks, aisles, sprinklers and required clearances set the boundaries of the layout.
Small layout details can change the count
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60 pallet positions became 80
On a Waukesha project, a second measurement changed the workable layout from 60 to 80 pallet positions before material was ordered.
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Density has to match access
More positions are not useful if the storage method slows rotation, hides inventory or conflicts with the lift equipment and SKU profile.
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The building sets the boundaries
Clear height, columns, docks, doors, sprinklers and required clearances can change the count before rack type is considered.
A ROUGH COUNT IS ENOUGH TO START
What we need to understand
Better data sharpens the result, but you do not need a finished analysis before the first conversation.
- Current, average and peak pallet counts
- Pallet dimensions, load heights, weights and overhang
- SKU count, velocity, lot control and access requirements
- Existing rack elevations and building floor plans
- Clear height, column grid, docks, doors, obstructions and sprinkler clearances
- Lift equipment, aisle needs, staging areas and growth assumptions
IMAGINE
Turn pallet data into layout options
We measure the space, review the load profile and compare two or three layout directions. 2D concepts, 3D models and VR make capacity, access and building constraints easier to review together.
INTEGRATE
Compare the right storage methods
Selective rack, pallet flow, pushback, drive-in, pallet runner and other systems solve different access and density needs. We source across multiple manufacturers and compare fit, lead time, price and long-term value.
IMPLEMENT
Carry the capacity plan into the field
Permitting, freight, rack modifications, protection and installation all affect the finished count. Our in-house install team and project oversight keep the approved layout connected to the jobsite.
How do we know how many pallet positions we need?
Start with current, average and peak inventory, then add known growth and operating requirements. We also separate reserve, staging and active pick needs so one rough total does not hide how the warehouse actually works.
Can existing rack be reconfigured to add capacity?
Sometimes. The answer depends on the rack system, condition, available components, load requirements, clearances and the proposed configuration. A site review and the right technical checks come before any modification is approved.
Which high-density rack system creates the most positions?
There is no universal best system. Pallet flow, pushback, drive-in and pallet runner trade direct access, rotation, lane depth, load consistency and equipment requirements differently. We compare them against the inventory and workflow.
Do we need a larger building?
Not always. Reconfiguration, different storage methods, better use of clear height or moving small parts into another system may create usable capacity. If the building remains the constraint, the analysis also makes that clearer.
Can Two3 complete the installation outside Wisconsin?
Yes. Two3 has already completed installations in 33 states and supports warehouse projects nationwide.
