Warehouse Shelving vs Pallet Racking: How to Choose the Right Storage System

Choosing between warehouse shelving and pallet racking is more than just picking the one that fits. The right system boosts picking speed, protects stock, and cuts damage, while the wrong choice creates bottlenecks and expenses.

Here’s a practical way to decide.

The quick difference

Warehouse shelving is designed for hand-picked inventory, including cartons, totes, parts bins, archives, and small, fast-moving items. It’s ideal when people walk the aisles and pick individual units.

Pallet racking is built for palletised loads handled by equipment (reach trucks, forklifts). It’s best when your stock is stored and moved as full pallets, or when you need vertical storage for bulk.

Start with your stock profile

Ask these questions: Do you store pallets? If so, you’ll almost always need pallet racking (at least for bulk storage).

• Do operatives hand-pick items?
  If yes, you’ll want warehouse shelving (or shelving as a pick face in front of racking).
• Do you handle both bulk and pick inventory?
  Most busy warehouses are hybrid: racking for reserve stock and shelving for fast picks.

Space & layout: think about flow, not just capacity

Storage isn’t ‘set and forget’. Consider:

• Aisle widths based on your handling equipment and turning circles
• Pick paths (can staff move without crossing forklift routes?)
• Future growth (can you add bays/levels later without redesigning everything?)

A slightly lower capacity layout that improves flow often outperforms a ‘packed to the rafters’ layout.

Load ratings & safety basics (don’t skip this)

Whether it’s shelving or racking, the golden rule is: know your load capacity and stick to it. Overloading, uneven loading, or using damaged components can create a serious risk.

In impact-prone areas (end-of-aisle areas and tight turning points), consider rack protection, such as column guards, barriers, and end-of-aisle protectors.

Inspections: build a routine

Do quick visual checks for:

• dents/bends to uprights
• missing locking pins/clips
• loose floor fixings
• damaged beams or shelves

For UK warehouses, it’s also worth bookmarking HSE’s warehousing and storage guidance (HSG76) as a baseline reference for safe storage practices.

SEMA also highlights the importance of formal racking inspections (commonly at least annually by a qualified inspector).

In summary: For fast-moving small items picked by hand, use shelving. For palletised bulk and vertical storage needs, pallet racking is best. Most operations benefit from a hybrid setup: racking for reserves and shelving for picks. Decide based on your item types and your team's workflow.

• Shelving: small items, hand-pick operations, workshops, archives
• Pallet racking: for bulk pallets and vertical storage needs.
• Hybrid: racking for reserve + shelving for pick faces (often the sweet spot)

Speak to the Strip Curtains Direct team about shelving vs racking, load signage, and protection options — we’ll help you build a safer, more efficient layout.

Call us on: 0333 999 7171

Or email us at: sales@stripcurtainsdirect.co.uk