Push Back Racking Systems

Push back racking is a high density pallet storage system that stores 2 to 5 pallets deep in each lane on carts riding inclined rails. The forklift works only from the front aisle. Each new pallet pushes the earlier pallets back, and when the front pallet is removed, gravity rolls the next one forward. It gives warehouses density without the forklift entering the rack. FunYa engineers every system to your pallet size and loads.

Key benefits:

• Store 2 to 5 pallets deep per lane and cut aisle space against selective racking
• Load and unload from one aisle so forklifts travel less and cycle faster
• Every lane stays independent, giving better selectivity than drive in racking
• Gravity does the work: no motors, no controls, no power supply needed
• Cold storage ready, with galvanized finish options for freezer environments
• Factory direct engineering with 2D and 3D layout drawings before production

What Is Push Back Racking?

Push back racking is a dynamic pallet storage system in which pallets rest on nested carts that roll along rails set at a slight incline. The forklift loads from the front aisle only. The first pallet goes onto the top cart, the second pallet pushes that cart back up the incline, and the process repeats until the lane is full. When the front pallet is picked, gravity pulls the remaining carts forward so the next pallet presents itself at the pick face. 

The last pallet stored is always the first one retrieved, which makes push back racking a LIFO system: last in, first out. Our push back racking category shows the range FunYa builds.

The LIFO loading and unloading sequence

Loading starts at the aisle. The forklift sets the first pallet on the front cart. The next pallet is driven against the first one and pushes the whole nested cart train one position deeper. Each additional pallet pushes the train further back until the lane holds its full depth. Unloading reverses the flow: the forklift takes the front pallet, the carts roll forward on the incline, and the next pallet arrives at the aisle ready for picking.

The inclined rail and nested cart mechanism

Each lane holds one rail pair per level, inclined about 3 degrees toward the aisle. The carts nest inside each other like telescoping frames, each riding on steel wheels. The top cart carries the front pallet position, and every cart behind it carries one deeper position.

Key Features of Push Back Racking

Nested carts that ride the rails

The cart train is the heart of the system. Each cart is a welded steel frame on wheels, sized to carry one pallet, and the carts nest so the whole train collapses to the front of the lane when empty. See the mechanism on our push back pallet racking product page.

Rail types: structural tube, I beam, and C channel

Structural tube rails give a clean enclosed running surface that sheds debris. I beam rails suit heavier pallet loads with their deep section. C channel rails offer an economical option for lighter duty lanes.

Full selectivity at every lane

Unlike drive in racking, where deep lanes bury pallets behind each other, push back racking gives every lane its own pick face at the aisle.

Single aisle operation

Every putaway and every pick happens from the front aisle. Forklifts never enter the structure, which removes the most common cause of rack damage in deep lane systems. Aisles stay clear and operators work faster because every pallet comes to them.

Built for cold storage

Push back racking earns its place in freezers. High density shrinks the refrigerated footprint. The single aisle layout limits door openings and keeps forklift traffic out of the cold zone. For freezer builds FunYa specifies hot dip galvanized finishes against condensation and confirms low temperature steel with the engineering team.

Ứng dụng điển hình

Food and beverage distribution. Dated stock with medium SKU counts fits the LIFO flow well.

Kho lạnh và kho đông lạnh. Density cuts refrigerated volume, and the gravity mechanism works reliably at low temperatures with no powered parts to fail.

Retail distribution centers.

Kho lưu trữ đệm sản xuất. Work in progress and raw materials sit close to the line in deep lanes, with forklifts cycling from a single aisle.

3PL and contract logistics.

Building materials and hardware.

Thông số kỹ thuật

Available Configurations

Lane depth: 2, 3, 4, or 5 pallets deep

Depth is the first decision. Two deep suits operations that want a small density gain with minimal equipment cost. Three and four deep are the most common, balancing density against cart cost per position. Five deep maximizes the footprint for SKUs with high pallets per SKU.

Rail and cart builds for different pallet weights

Light pallets run well on C channel rails with standard carts. Medium and heavy pallets move to structural tube or I beam rails with reinforced carts and heavier wheels. The engineering team matches the running gear to your maximum pallet weight, so the carts roll smoothly for years instead of wearing prematurely.

Finishes for ambient, humid, and freezer environments

Ambient warehouses use the standard powder coated finish in blue and orange, with custom RAL colors available. Humid sites, food plants with washdown, and outdoor covered storage call for hot dip galvanizing. Freezer builds combine galvanizing with low temperature steel confirmed during engineering.

Thuận lợi

Density without entering the rack. Push back racking stores up to five pallets deep while the forklift never leaves the aisle.

Selectivity that drive in cannot match. Every lane has its own pick face, so any SKU is reachable without digging.

Faster cycles, less damage. Cycle times drop and the rack structure avoids the constant impacts of drive in operation.

No power, no controls, no maintenance contracts. Gravity moves the pallets. There is nothing to wire, program, or service on a schedule, which keeps lifetime operating cost low.

A step toward automation without the leap. Warehouses that are not ready for shuttle or AS/RS investment gain serious density with a purely mechanical system that operators learn in a day.

Planning Considerations

Push back racking is a LIFO system, so start with the honest question: does your stock tolerate last in, first out? If you need strict first in, first out rotation for expiry dated goods, kệ pallet dòng chảy trọng lực gives true FIFO on inclined roller lanes and is the better fit. If most SKUs hold only one or two pallets, selective racking gives full access at lower cost per position than deep lanes ever will.

Pallet quality matters more here than in selective racking. Carts ride on pallet bottom boards, so broken boards, missing blocks, or inconsistent pallet sizes cause poor tracking and jams. Standardize on sound pallets, preferably a single footprint per lane, before committing to push back.

Match lane depth to pallets per SKU. A five deep lane holding two pallets wastes three cart positions. Count pallets per SKU across your inventory: lanes perform best when one SKU fills most of a lane. Mixed SKU lanes defeat the density purpose.

Plan forklift push force. Loading the second and deeper pallets means pushing the cart train up the incline. Confirm with the engineering team that your forklifts have the capacity and traction for the deepest lanes at maximum pallet weight, especially on polished freezer floors.

Compare the density alternative. If your operation can accept the forklift entering the rack and needs the lowest cost per position in very deep lanes, double wide drive in pallet racking stores deeper for less. Push back racking earns its premium through selectivity, speed, and damage reduction.

Custom Racking Support for Your Project

FunYa manufactures every push back system in its own 15,000 square meter production base in Nanjing, with six workshops covering cold rolling, cutting, stamping, welding, automated coating, and finished goods storage.

Every project starts with engineering. Share your pallet size, maximum pallet weight, SKU profile, and warehouse dimensions, and the team returns 2D and 3D CAD layout drawings with a load review before production. Installation guidance ships with every order, and the support team stays available after handover for spare carts, wheels, and rails. Talk to a racking specialist about your push back project.

Related Warehouse Storage Systems

• Kệ pallet kiểu đẩy lùi: nested carts on inclined rails, up to 5 pallets deep
• Double Wide Drive In Pallet Racking: two pallets side by side per lane for extreme density at lower cost per position
• Hệ thống giá kệ pallet chảy tự do: inclined roller lanes for true FIFO pallet rotation
• Push back racking category: the full push back range from FunYa

Câu hỏi thường gặp

1. How does push back racking work?

Pallets sit on nested carts that ride on rails inclined about 3 degrees. The forklift places the first pallet on the top cart, and each following pallet pushes the earlier ones back up the incline. When the front pallet is removed, gravity rolls the next cart forward to the pick face.

Loading and unloading both happen from the same front aisle, so the forklift never enters the rack. The last pallet stored is the first one retrieved, which makes the system LIFO.

2. What is the difference between push back racking and drive in racking?

In push back racking the forklift stays in the aisle and pallets move on carts, while in drive in racking the forklift drives into the lane itself. Push back gives every lane its own pick face, so selectivity is far better.

Drive in racking can store deeper lanes at lower cost per position, but the forklift inside the structure slows cycles and risks more rack damage. Choose push back when you need density plus reasonable selectivity and faster stock rotation per lane.

3. How many pallets deep can push back racking go?

Standard configurations run 2 to 5 pallets deep per lane. Each added depth position needs its own nested cart, so deeper lanes cost more per position.

Most warehouses settle on 3 or 4 deep as the balance between density gain and equipment cost. The right depth depends on pallets per SKU: lanes work best when one SKU fills most of a lane.

4. Can push back racking work in a freezer warehouse?

Yes. Push back racking suits cold storage well because high density cuts the refrigerated footprint, and the single aisle layout limits door openings and forklift traffic inside the cold zone.

Specify hot dip galvanized finishes for condensation resistance and confirm low temperature steel with the engineering team. Share your operating temperature in the RFQ so the materials are specified correctly.

Request a Customized Push Back Racking Quote

• Warehouse dimensions and clear height. These set the rack footprint and how many levels fit.
• Pallet size and maximum weight per pallet. These size the carts, rails, and frames for safe operation.
• Pallets per SKU and total SKU count. These set the right lane depth and lane count for your inventory.
• Required storage capacity. This defines how many lanes and bays the layout needs.
• Forklift type. This confirms push force and aisle width for single aisle operation.
• Destination country. This sets export packaging, shipping terms, and applicable standards.

Send your details by WhatsApp at +86 13357805048 or email [email protected]. The team responds with 2D and 3D drawings and a project quotation, so your push back racking arrives engineered for your operation.