Double-Deep Racking
Increase your pallet capacity by up to 35% without expanding your footprint. By storing pallets two deep, double deep racking provides a high-density setup for high-volume operations—allowing you to store more inventory in the same space while keeping pallets accessible.
What is Double-Deep Racking?
Double deep racking is a high density pallet racking system designed to optimize your warehouse space. In this setup, pallets are stored two deep per side—one directly in front of the other.
Built using standard racking components with deeper frames, this layout eliminates alternating aisles to drastically increase your cubic storage density. In fact, it increases storage capacity by ~25–35% over standard selective rack. Businesses can make the most of their available floor footprint without compromising on workflow efficiency.
Key Operational Note:
Because of the two-deep configuration, this system operates on a LIFO (Last In, First Out) inventory flow. It requires specialized material handling equipment, such as double-reach trucks or forklifts with pantograph extensions, to place and retrieve the back pallet.
Where Double-Deep Racking Shines
Double-deep racking is highly effective when your inventory movement is planned, consistent, and volume-heavy. Here are the primary use cases:
High-Volume, Same-SKU Storage:
This system is perfect when you have multiple pallets of the same product. Because the front pallet doesn’t block access to a different SKU, you reduce unnecessary reshuffling while maximizing cubic space.
Facilities with Limited Floor Space:
Ideal for urban warehouses, leased facilities, or distribution centers nearing capacity. When you cannot expand your footprint but need to add pallet positions quickly, fewer aisles mean more rack rows and better use of your horizontal space.
Seasonal or Buffer Storage:
This high-density pallet racking configuration is excellent for buffer inventory that doesn’t require constant, everyday access. Slower-moving inventory can be stored securely behind fast movers, reducing congestion in your active selective rack zones. (Examples: Seasonal product lines, promotional inventory, or safety stock.).
Full-Pallet In / Full-Pallet Out:
Double-deep racking is typically not ideal for individual piece-picking. Instead, it is an excellent pallet storage solution designed for bulk replenishment stock or reserve inventory that eventually feeds your pick modules.
Built for Industries That Move Volume
E‑Commerce
Maximizes bulk reserve storage to feed high-velocity pick modules without increasing your facility footprint.
Manufacturing
Ideal for batch-produced finished goods, providing deep-lane storage that simplifies high-volume staging.
Big & Bulky
The standard for crated furniture and appliances where high-density storage of identical units is the priority.
Food & Beverage
Maximizes chilled or ambient space for bulk packaging and high-turnover, non-perishable inventory.
Is Double-Deep Racking Right for You?
It is a Perfect Fit If:
- You have high pallet counts per SKU.
- Your operation naturally relies on LIFO (Last In, First Out) inventory flow.
- Your facility already utilizes (or is planning to utilize) double-reach or pantograph reach trucks.
- You need to store finished goods or reserve inventory.
You Should Look at Alternatives If:
- You require strict FIFO (First In, First Out) rotation, such as with expiration-dated goods.
- You have many different SKUs, but very low pallet counts for each.
- Your operation relies exclusively on standard counterbalance forklifts.
- You require constant, direct access to every single pallet at all times.
check out our Standard Rack, Push-Back Rack, or Pallet Flow systems instead
Ready to Optimize Your Storage Space?
USSI handles the design, engineering, and installation of industrial pallet racks, including fully customized double deep racking systems. Projects range from retrofitting active distribution centers to planning seasonal overflow spaces and laying out new warehouse facilities. System configurations are determined strictly by the facility’s existing footprint, pallet dimensions, and specialized forklift capabilities.