Maximising Efficiency: Understanding Block Stacking and Its Impact on Warehouse Operations
What is Block Stacking?
Block stacking, or floor pallet stacking, is a method where loaded pallets are placed directly on the floor and stacked to a stable height without any storage equipment. Lanes are created for access to different stock keeping units (SKUs).
The maximum stacking height depends on several factors:
Load strength (how much weight can be stacked on)
Load weight
Load stability
Pallet conditions
Safety limits
Weather conditions
Warehouse clearance heights
These factors must be carefully considered to ensure safe stacking levels.
A key limitation of block stacking is that SKUs are only accessible in a Last In First Out (LIFO) manner. This method is space-intensive, requiring large areas for storage.
When loads are removed, underutilised space, known as honeycombing, is created and cannot be used until the entire lane is cleared. Therefore, careful planning of lane length and depth is essential to maximise utilisation based on stock output levels for each SKU.
Block stacking is cost-effective and flexible, requiring no investment in pallet racking systems. It can be set up wherever there’s available floor space, adapting easily to changing storage needs. Forklifts can stack and unstack more quickly compared to selective pallet racking systems, making block stacking efficient and popular in many industries.
However, it’s only suitable for stable and safe loads. For unstable loads, pallet racking or stacking frames are better options. Forklift operators must stack loads squarely to maintain stability.
In conclusion, block stacking is a versatile and cost-effective method for warehouse storage, offering significant flexibility and efficiency.
By placing loaded pallets directly on the floor and stacking them to a stable height, businesses can adapt to changing storage needs without investing in additional equipment.
However, it’s crucial to consider factors such as load strength, weight, stability, and safety limits to ensure safe stacking levels.
Despite its benefits, block stacking has limitations, including the Last In First Out (LIFO) access method and the potential for underutilised space due to honeycombing. Careful planning of lane length and depth is essential to maximise space utilisation.
While block stacking is ideal for stable loads, alternative methods like pallet racking or stacking frames should be used for more unstable items. Overall, block stacking remains a popular choice in many industries due to its efficiency and adaptability.
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