Push-back is a high-density storage solution using nested wheeled carts that move along slightly inclined rails. To achieve optimal productivity and ensure worker safety, your warehouse team should be fully trained on proper push-back racking operating procedures. Here's our step-by-step Push-Back Pallet Rack Training video covering - operating procedures, system loading and unloading, and troubleshooting hang-ups.

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What is Push-Back Rack?
Push-back pallet rack combines the density of drive-in rack with the selectivity of selective pallet rack. The uniqueness of push-back rack is the series of mobile carts that ride on rails within each row. A loaded pallet is placed on the upper cart within the system. As the next pallet is loaded, the forklift gently pushes the first pallet load back, exposing the 2nd cart. The process continues until all carts are used (typically 3-4 deep), with the last pallet resting on the rails. As each pallet is extracted the subsequent pallet flows to the aisle face for selection, allowing for highly productive pallet retrieval.

Here's How to Load the Push-Back System:
--Lift the pallet load approximately 3 to 4 inches above the first cart. Enter the rack and place the pallet centered on the first cart… then slowly back out.
--Next, line up the bottom boards of the 2nd pallet with the bottom boards of the first, just above the cart.
--Gently push back the 1st pallet as you enter the rack --centering the 2nd pallet over the exposed cart, and so on.
--If the pallet isn't centered correctly --leaving additional space at the front of the cart, you will risk misloading the next pallet. If this occurs, back out of the system and re-load the misaligned pallet.
--The last pallet won't sit on a cart. It will sit directly on the push-back rails. Once again, center the pallet in the lane and lower it onto the rails behind the pallet stops.
--If they're provided in your system, pallet stops can be used to help center the pallet as well as to absorb impact from rear forces.

How to Unload the Push-Back System:
--Center the forklift with the front pallet and slowly enter the lane. Lift the pallet 3" to 4" so that it clears any pallet stops or obstructions. Then slowly extract the pallet. The subsequent loads and carts will glide forward to the aisle face.
--A bumper plate is installed to ensure a low-impact cart stop, however... the operator should control the speed at which the subsequent pallets in the system glide forward by slowing backing out.
--Follow the steps to unload the remaining pallets off the lane.

See the video for maintenance and troubleshooting tips.

Push-back pallet rack is a last-in/first-out (LIFO) warehousing storage solution and is most often used for LIFO inventory rotation, but can be used for first-in/first-out (FIFO) depending on how the product comes in and out of the warehouse, as well as the depth of the system. For example, produce facilities with fast inventory turns use 2-4 deep push-back with FIFO rotation – all pallets are loaded to fill a push-back lane at the same time, then subsequently picked for shipment together as well. Additional vertical clearance is needed per level to accommodate stacked carts which may limit the number of vertical positions available. To learn more, see our video showing push-back in action.

Advantages | Considerations:
High-density pallet storage system
Requires limited number of aisles
Ideal for high-volume, low-SKU applications
LIFO stock rotation
Minimized travel time for load and unloading
Full SKU selectivity for every pallet position