roll out rack

Why Conventional Racking Systems Compromise High-Purity Materials

In precision manufacturing, particularly for industries like pharmaceuticals, semiconductors, and food processing, the physical state of raw materials is as critical as their chemical composition. The challenge lies in a paradox: the materials, such as 316L stainless steel tubes, are heavy and structurally robust, yet their surfaces are microscopically delicate. Standard storage practices, like stacking on the floor or in static cantilever racks, create a conflict between handling efficiency and material preservation. The primary cause of damage is the interaction with forklifts and the friction of materials sliding against steel arms or each other. This isn't just a cosmetic issue; it's a direct threat to product integrity and compliance.

The Hidden Cost of a Single Scratch

A scratch on a high-purity stainless steel tube is not a minor imperfection. It's a microscopic trench that compromises the material's most critical feature: its passive layer. This ultra-thin, invisible layer of chromium oxide is what gives stainless steel its corrosion-resistant properties. When a forklift tine scrapes against a tube or a bundle is dragged from a static rack, this protective layer is breached. In a pharmaceutical application, this scratch becomes a potential harborage point for bacteria and biofilm, making the tube impossible to properly sterilize and rendering it non-compliant with strict standards like ASME BPE. The result is not just a rejected part but the potential for an entire production batch, worth hundreds of thousands of dollars, to be scrapped. The value isn't in the steel itself, but in its flawless surface finish.

Shifting the Paradigm: From Horizontal Dragging to Vertical Lifting

The most effective way to protect sensitive surfaces is to eliminate the source of friction and impact entirely. A roll out rack, also known as a crank-out or telescopic cantilever rack, is engineered to achieve this by fundamentally changing how materials are accessed. Instead of driving a forklift into a narrow aisle to retrieve materials, the rack itself presents the material to the operator in an open, accessible space.

The Power of 100% Full Extension

The core innovation of a roll out rack is its ability for each storage level to extend fully—100% of its depth—out from the main frame. Using a manual crank or an electric motor, a single operator can smoothly move a shelf holding several tons of material into the aisle. This action places the entire bundle of tubes or bars directly under the clear vertical path of an overhead crane.

Achieving True "Non-Contact" Logistics

With the material fully extended, an overhead crane can lower soft nylon slings or a vacuum lifter directly onto the load. The material is then lifted vertically, with no sliding, scraping, or metal-on-metal contact. It never touches another bundle or the rack arms during retrieval. This process of vertical lifting effectively decouples the storage system from the damaging forces inherent in forklift operations, preserving the critical surface finish from the moment it arrives at your facility until it reaches the production line.

Direct Impacts on Your Daily Operations

Implementing a crane-accessible roll out rack system delivers immediate and tangible improvements to the workflow, safety, and efficiency of your facility. These are not abstract financial benefits; they are practical changes that operators and managers experience every day.

From Risky Guesswork to Guaranteed Quality

The "non-contact" handling method provides a procedural guarantee that high-value materials will reach the manufacturing stage in pristine condition. This eliminates the "hidden factory" of inspecting for damage, buffing out minor scratches, or rejecting entire lengths of expensive material due to handling errors. It transforms material storage from a source of quality risk into a reliable step in the value chain.

Instant Access: Reclaiming Wasted Time

In a conventional setup, retrieving a specific bundle from the bottom of a stack can take 15 to 25 minutes of "secondary handling"—moving other bundles out of the way, finding a place to set them, getting the target bundle, and then restacking everything. With a roll out rack, every level is independently accessible. The retrieval time is a predictable 2-5 minutes, every time. This speed directly translates into increased uptime for expensive machinery like CNC centers and laser cutters that are no longer idle while waiting for material.

Comparative Analysis: Crane-Served vs. Forklift-Served Storage

Dimension	Traditional Forklift Storage System	Roll Out Rack with Overhead Crane
Surface Integrity	High risk of scratches and impact from forklift tines and material sliding.	Near-zero risk. Soft slings and vertical lifting ensure no contact or sliding.
Retrieval Cycle	Slow (15-25 minutes). Requires moving obstructing materials (secondary handling).	Fast (2-5 minutes). 100% selectivity provides direct access to any level.
Space Utilization	Low. Requires wide aisles (4-6 meters) for forklift turning radius.	Extremely high. Aisle width is determined by load, not vehicle. Can save over 50% of floor space.
Operator Safety	High risk due to blind spots, load instability, and tight maneuvering in aisles.	High safety. Operator stands clear of the load with excellent visibility and control.
Contamination Control	Poor. Forklift tires generate dust; potential for fluid leaks.	Excellent. Electric cranes operate cleanly with no ground-level disturbance.

Frequently Asked Questions

1. What makes a roll out rack inherently safer than a standard cantilever rack?

Safety is improved in two key ways. First, by using an overhead crane, the operator is positioned away from the suspended load, not underneath or adjacent to it as with a forklift. This greatly reduces the risk of crushing or pinning injuries. Second, the ergonomic crank mechanism allows a single person to move several tons of material with minimal physical effort, reducing the risk of musculoskeletal injuries associated with manually handling heavy stock.

2. How does this system help with material traceability and inventory management?

A roll out rack provides 100% selectivity, meaning each shelf acts as a discrete storage location. This allows for perfect lot control. You can assign a specific heat number or production batch to a single shelf, often with dividers for sub-organization. When an audit occurs or a specific lot needs to be pulled, there is no question about its location or identity, unlike in a commingled floor stack.

3. Can a roll out rack handle different lengths and shapes of material in the same unit?

Yes. The open-faced design of the cantilever arms is ideal for storing a mix of materials. You can store long bundles of pipe on one level, shorter bar stock on another, and even use baskets or custom fixtures on a third level for storing off-cuts or irregular components. The system's flexibility makes it a highly efficient solution for high-mix, low-volume storage environments like job shops or service centers.

4. Is a manual crank or an electric motor better for a roll out rack?

The choice depends on frequency of use and load weight. A manual crank is a simple, cost-effective, and maintenance-free solution perfect for storage areas with infrequent access or for arm capacities under 3,000 lbs. For high-throughput applications, such as feeding a laser cutter or press brake, or for extremely heavy loads like tooling and dies, an electric motor with pendant or remote control is superior as it reduces cycle times and operator fatigue.

5. How does a roll out rack integrate with existing overhead cranes?

These racks are designed to work seamlessly with standard overhead bridge cranes. The 100% extension ensures the material is moved completely out from under the rack structure, providing clear, unobstructed vertical access for the crane's hoist. The system simply requires adequate headroom above the rack for the crane to operate safely. It leverages an asset—the overhead crane—that many industrial facilities already possess.