Storing goods on the warehouse floor might seem like the path of least resistance, particularly when you’re dealing with components or materials that don’t sit neatly on a standard pallet. Yet floor storage wastes vertical space, restricts picking access, and creates bottlenecks that slow operations down. Integrating steel stillages with pallet racking systems offers a practical way to reclaim that lost capacity while keeping items organised, protected, and easy to access.
We explain how stillages and racking work together, the operational benefits of combining them, the key factors to consider when planning your setup, and how to maintain the system once it’s in place.
How Do Stillages Work Within Pallet Racking Systems?
Steel stillages are robust storage containers designed to hold, protect, and transport a wide range of materials – from small components and irregularly shaped parts to heavy automotive assemblies. When housed within a pallet racking system, stillages are deposited into bays in a similar manner to standard pallets, typically using a forklift to place and retrieve them.
The difference is that stillages contain and secure goods that would otherwise be difficult to rack. Items that might shift, roll, or topple on a flat pallet are held firmly within the stillage’s steel frame, mesh sides, or solid walls. Warehouse operatives can then pick directly from the stillage while it sits in the racking bay, reducing unnecessary handling steps.
This approach occupies both the full footprint and headroom of your warehouse through a multi-tier system – something floor storage simply doesn’t afford.
What Are the Benefits of Combining Stillages with Racking?
Bringing stillages and racking together delivers measurable improvements across several areas of your operation.
Maximised Vertical Storage Capacity
Stackable stillages already make good use of height, but placing them within a racking structure takes this further. Racking provides defined levels at calculated intervals, allowing you to store stillages at multiple tiers safely and access each one independently. You free up valuable floor space without compromising how quickly operatives can reach inventory.
Improved Picking Efficiency
When stillages sit on the warehouse floor, operatives often need to bend, reach, or move other units to access what they need. Racking positions stillages at ergonomic heights, increasing the size and accessibility of the picking face. This reduces handling time and supports faster throughput, particularly in busy distribution or manufacturing environments.
Enhanced Product Protection
Steel stillages already provide excellent containment for fragile, heavy, or irregularly shaped goods. Housing them within a racking system adds a further layer of stability, preventing accidental knocks from passing vehicles or adjacent stock movements. For industries handling expensive components (automotive parts, precision instruments, or electronic assemblies), this combination significantly reduces the risk of costly damage.
Streamlined Inventory Management
Standardised stillage dimensions work seamlessly with racking configurations, creating a consistent, repeatable system. Each bay holds a known quantity in a known location, simplifying stock audits and improving accountability across the warehouse.
What Factors Should You Consider When Planning Your Setup?
Getting the integration right from the outset saves time, money, and potential safety issues further down the line.
Load Capacity
Determine the maximum weight each stillage will carry and ensure your racking is designed to support those loads at every tier. Account for the weight of the stillage itself as well as its contents – steel construction adds durability but also mass that must be factored into racking specifications.
Stillage Dimensions
Ensure your stillage dimensions align with the racking bay widths and depths. Bespoke stillages can be manufactured to fit existing racking configurations, or racking can be specified alongside new stillages to create a fully optimised system from the start.
Forklift Access
Consider aisle widths and the type of forklift equipment your team uses. Stillages with integrated fork pockets allow for safe, efficient placement, but operatives need sufficient clearance to manoeuvre at height without risk.
Beam Height Adjustments
Raising or adjusting beam levels may be necessary to accommodate taller stillages or to position them at heights that suit your picking processes. Any changes to beam positions must account for load distribution across the racking structure.
How Should You Maintain the System?
Regular inspections of both stillages and racking are essential to ensure continued safety and performance. Check for signs of damage such as bent frames, cracked welds, or rust that could compromise structural integrity. Address any issues promptly – a damaged stillage sitting in a loaded racking bay creates risks that extend well beyond the unit itself.
Keep stillages clean and store them properly when not in use. If units sustain damage through heavy use, professional repair services can restore them to full working condition rather than requiring complete replacement.
Partner with Range Storage for Stillages Built to Work with Your Racking
Range Storage Equipment Ltd has been manufacturing stillages and storage solutions in our West Yorkshire factory since 1979. Every stillage we produce is designed and built in-house, giving us complete control over quality, dimensions, and lead times.
Whether you need standard stillages sized to fit existing racking or bespoke units engineered to your exact specifications, our team can help. We also offer a repair and maintenance service to keep your stillages performing throughout their working life.
Contact us on 01274 736363 to discuss how our stillages can integrate with your racking systems for maximum efficiency.
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