Why is layout about more than the number of pallet positions?
When planning a warehouse, the first question is usually how many pallet positions will fit. Just as important is how quickly goods move through the space. Two warehouses with the same number of positions can work very differently: in one, forklifts travel short and clear routes; in the other, they cross paths, wait and cover needless distance.
Which direction should goods flow?
The basic rule is that zones follow each other: goods-in, storage, picking, packing and dispatch. The two most common layouts are:
- Through flow (I-flow) – goods-in on one side, dispatch on the opposite side. Suits sites with many docks and high throughput.
- U-flow – goods-in and dispatch on the same side. Makes better use of docks and the space next to them, and fast movers sit close to both zones.
Which is better depends on where your doors and docks are, not on a general rule.
Where should fast-moving goods go?
The most frequently picked items belong in the most accessible positions: on lower levels and close to dispatch. An ABC analysis groups goods by how often they are issued. A items get the best locations, C items the upper levels and the more distant runs. This shortens travel without adding a single rack.
How wide should the aisles be?
Aisle width is set by the forklift and the load dimensions, not the other way round. Typical, orientational values for pallet racking:
| Equipment | Typical aisle width |
|---|---|
| Counterbalance forklift | approx. 3.2 – 4.0 m |
| Reach truck | approx. 2.6 – 3.2 m |
| Very narrow aisle (VNA) truck | approx. 1.6 – 2.0 m |
The exact figure depends on the truck model, pallet size and how loads are placed, so it is always checked against the forklift manufacturer's data.
How should rack runs be arranged?
- Double-entry runs in the middle and single runs along the walls give the most positions per aisle.
- Where building columns allow, runs are placed parallel to the direction of travel towards dispatch.
- Cross aisles in long runs shorten travel and act as escape routes.
- Building columns, doors, lighting and sprinklers determine where runs can go and how many levels make sense.
How do you leave room to grow?
A good layout plans for extension: a free zone for extra runs, the option to add levels, or a mezzanine above the picking area. If this is planned from the start, a later extension does not mean reorganising the whole warehouse.
How does EL-FAM plan a layout?
EL-FAM surveys the space, analyses the flow of goods and prepares a layout with load calculations, then manufactures and installs the system. Send us a drawing or the hall dimensions, door positions and details of your goods, and we will propose a layout.
Frequently asked questions
How wide should aisles between pallet racks be?
It depends on the forklift. As a guide, around 3.2 to 4 m for a counterbalance forklift, 2.6 to 3.2 m for a reach truck and 1.6 to 2 m for a very narrow aisle truck.
Which is better, through flow or U-flow?
It depends on where your doors and docks are. Through flow suits high throughput with docks on opposite sides; U-flow makes better use of docks on one side.
Where should the most frequently picked goods be stored?
On lower levels and as close to dispatch as possible. An ABC analysis shows which items deserve the best locations.
Can the layout of an existing warehouse be changed?
Yes, but the new layout is checked against rack capacity, floor condition and the position of services before anything is moved.
