Storing big, heavy inventory in a tall warehouse sounds simple—stack it high and call it a day.
But anyone who’s actually worked around bigger stock areas knows that it’s not like the TikTok videos you’ve probably watched. There are a lot of things you need for everything to run smoothly.
Before you face the consequences of damaged goods, frustrated workers, and, eventually, unhappy customers, check out these solutions for handling heavy inventory safely.
Get the Right Racking System
Tall storage facilities need racking that can handle the weight. Standard shelving won’t cut it when you’re dealing with thousands of pounds per pallet.
What to look for:
Selective pallet racking: They are good for easy access to heavy loads.
Double-deep racking: It saves you space but requires deep-reach forklifts.
Drive-in racking: Choose this if you work around large quantities of the same product.
Cantilever racking: These are great for lengthy items like lumber or pipes.
Use Heavy-Duty Pallets
Not all pallets are built the same. Cheap, flimsy ones will break under too much weight, which can damage products and put workers at risk.
Better options include:
- Hardwood pallets
- Plastic pallets
- Metal pallets
Inspect pallets regularly. A single weak board can cause a full load to collapse.
Invest in Proper Lifting Equipment
Moving heavy inventory up and down tall racks isn’t a job for just any forklift. You need machines built for the task.
Best options for high storage:
Reach trucks: They extend their forks deep into racks.
Turret trucks: These trucks work well in narrow aisles with rotating forks.
Counterbalance forklifts: They can handle heavy loads on the ground and at mid-level heights.
If you’re expanding your fleet, check out new forklifts for sale. Used models can work, too, but always check their condition before buying.
Train Workers on Safe Lifting and Handling
Handling heavy inventory with decent equipment is not enough without knowing how to use it safely. Untrained workers are more likely to cause accidents, slow down operations, or damage inventory.
Make sure that employees get certified for forklift operation. They should also understand the weight distribution and load limits of each lifting equipment in the warehouse. Apart from being trained in proper stacking and retrieval, each machine operator must partner with spotters, especially when handling oversized loads.
A little training goes a long way in preventing damages and accidents.
Use Warehouse Management Software (WMS)
Guesswork doesn’t work when you’re managing tons of inventory. A WMS system helps track where everything is stored and the best way to retrieve it.
With WMS, you can:
- Reduce unnecessary movement by optimizing storage locations.
- Track inventory levels in real time.
- Automate stock rotation for better organization.
- It keeps operations smooth and prevents the nightmare of losing heavy products in the wrong spot.
Set Up a Safe Picking System
Retrieving items from tall shelves can be risky if done wrong. A proper picking system ensures safety and efficiency.
Best practices include:
- Using order pickers for mid-level storage.
- Implementing zone picking to avoid congestion.
- Keeping high-demand items lower for quicker access.
- Using barcode scanners to minimize picking errors.
- The less time spent reaching for heavy items, the better.
Regularly Inspect Racks and Equipment
Tall storage facilities put extra strain on racks, pallets, and forklifts. A weak structure can collapse under heavy loads.
Avoid expensive damage and safety risks through routine checks that include:
- Looking for bent beams or damaged racks.
- Inspecting forklifts for wear and tear.
- Checking pallet conditions before loading.
- Making sure weight distribution is balanced.
- A few minutes of inspection can prevent thousands in damages.
Plan for Warehouse Traffic Flow
Heavy inventory means heavy equipment moving around all day. If the warehouse isn’t set up for smooth traffic, congestion happens fast.
To keep things flowing:
- Designate separate paths for forklifts and foot traffic.
- Use one-way aisles to avoid collisions.
- Keep loading zones clear to prevent backups.
- Set speed limits for equipment in busy areas.
- A well-organized traffic plan prevents chaos and speeds up order fulfillment.
