Achieving Storage Density with Push-Back Racking

Interstate Chemical is a full-service chemical distribution company headquartered in Lakeland, Florida, serving manufacturers, industrial facilities, and commercial businesses throughout the region. Its operations include chemical distribution, custom blending, packaging, warehousing, and logistics, allowing customers to source products and related services through a single supplier. The company maintains an extensive inventory of industrial and specialty chemicals while supporting a wide variety of applications across multiple industries.

Efficient inventory management, dependable deliveries, and strict regulatory compliance are central to its daily operations. Because chemical products require specialized handling and storage, Interstate Chemical places significant emphasis on maintaining a safe, organized, and compliant warehouse environment. As the business continues to support growing customer demand, investing in storage systems that improve capacity while meeting safety requirements remains an essential part of its operational strategy.

Atlantic Rack installed a 2-deep push back racking system to increase storage density while maintaining direct access to pallet lanes. Unlike conventional selective racking, the push back system allows pallets to be stored two positions deep on inclined rails using nested carts. As a new pallet is loaded, it gently pushes the previous pallet toward the back of the lane. When a pallet is removed, gravity automatically advances the remaining pallet to the front, reducing forklift travel inside the storage area and improving loading efficiency.

To meet the facility’s fire protection requirements for storing acetone, the push back racks were equipped with in-rack water sprinklers integrated within the rack structure. This built-in fire suppression feature provides water distribution throughout the storage lanes, helping the system comply with applicable fire safety standards for high-hazard commodities while maintaining the benefits of high-density storage.

Selective pallet racking was installed to provide direct access to every pallet location, making it well suited for products that require frequent movement or inventory rotation. The system offers a flexible storage layout that accommodates different pallet sizes while allowing forklifts to retrieve any load without relocating surrounding inventory.

Its modular design also provides the ability to adjust beam elevations as storage requirements change, giving Interstate Chemical the flexibility to adapt the warehouse to future operational needs without replacing the existing rack structure.

Steel post protectors were installed at vulnerable rack uprights to reduce the risk of impact damage caused by daily forklift operations. Positioned around the base of rack columns, these protective barriers absorb low-level collisions that might otherwise damage structural components.

By shielding the rack uprights from accidental contact, post protectors help preserve the integrity of the storage system, reduce maintenance costs, and extend the service life of the installation while supporting a safer warehouse environment.

End-of-aisle rack protectors were installed to safeguard the most exposed rack locations from vehicle impacts. Rack ends are particularly susceptible to contact from forklifts during turning and pallet handling, making them one of the highest-risk areas within a warehouse.

These heavy-duty steel barriers create a physical buffer that helps prevent structural damage to the racking system, reducing repair costs and minimizing the potential for disruptions caused by accidental collisions.

• Increased warehouse storage capacity through the installation of a high-density 2-deep push back racking system.
• Maintained immediate access to inventory with selective pallet racking for fast-moving products.
• Integrated in-rack water sprinklers within the push back racks to meet fire protection requirements for storing acetone, a highly flammable liquid.
• Improved warehouse safety by protecting rack uprights with steel post protectors.
• Reduced the risk of forklift impact damage at high-traffic aisle ends with heavy-duty rack protectors.
• Enhanced overall warehouse organization, operational efficiency, and long-term durability of the storage system.
• Delivered a safer, more organized warehouse that supports long-term operational performance and future growth.