Transform your warehouse with a storage solution that adapts to your most challenging inventory. Our industrial stacking racks are engineered to handle unwieldy, crushable, or irregularly shaped goods—turning wasted vertical space into valuable, protected storage. Increase density, improve safety, and create a truly flexible warehouse environment.
In any warehouse or logistics operation, the greatest challenge isn't just managing space; it's managing awkwardness. Tires, fabric rolls, long pipes, and bulk bags share a common problem: they resist stable, dense storage. Traditional methods like floor stacking or fixed pallet racking often create more problems than they solve, leading to damaged products, wasted space, and operational bottlenecks. The solution lies not in forcing these items into a system that doesn't fit, but in adopting a system built for them: the stack rack.
For non-rigid or round items, direct stacking turns the force of gravity into a destructive agent. The weight of the items on top compresses, deforms, and damages the goods at the bottom. This isn't just a minor issue; it's a direct hit to your bottom line through product loss and reduced yield.
Floor stacking, or "block stacking," is the default for many operations, but it's deeply flawed for certain products. In the tire industry, the practice of "lacing" tires to maximize floor space causes irreversible bead deformation and flat-spotting on the bottom layers, rendering them unsafe. Similarly, textile warehouses see significant "yield loss" when the bottom fabric rolls in a pyramid stack are crushed into an oval shape, creating permanent creases that make meters of material unusable.
Standard pallet racks offer selectivity but are notoriously inefficient for non-standard loads. Forcing a large roll of carpet or a bundle of steel tubes into a bay designed for a 48" pallet results in massive amounts of unused vertical and horizontal space—the "wasted cube." You end up paying to heat, cool, and light a warehouse full of empty air, while your actual storage density remains critically low.
A portable stack rack, also known as a post pallet or stillage, fundamentally changes the physics of storage. It introduces a load-bearing steel frame—a skeleton—around your products. The weight of stacked layers is transferred through the vertical posts directly to the floor, not through the goods themselves. This simple change has profound consequences for your operation.
By removing the product from the structural equation, you can safely stack goods 4 or 5 units high, reaching the full clear height of your facility. This immediately multiplies your storage capacity on the same footprint by 400-500%. Because these heavy duty stack racks are not bolted to the floor, they create a dynamic storage environment. Your warehouse layout can be reconfigured in hours to accommodate seasonal inventory peaks, clearing entire sections for cross-docking or value-added services during slower periods.
The true power of a portable stacking pallet rack is its role as a piece of Returnable Transport Packaging (RTP). It seamlessly integrates the storage, handling, and transportation phases of the supply chain.
Products are loaded into the rack at the end of the production line and can stay in that same unit until they reach the end user. This "unitized flow" eliminates multiple manual handling steps, which are the primary cause of product damage, contamination, and labor-intensive repalletizing. Your goods are protected by a steel cage from the factory floor to the delivery truck, slashing damage rates to near zero.
The high cost of return shipping is what makes many reusable packaging systems economically unviable. Demountable post pallets solve this with a critical design feature: nesting. The corner posts can be removed, allowing the empty bases to be nested or stacked compactly. A single truckload can return 4-6 times the number of empty racks compared to assembled ones, reducing return freight costs by up to 80% and making a closed-loop supply chain a profitable reality.
The efficiency and safety of a stack rack system are rooted in specific engineering details that directly address common operational pain points.
| Feature | Operational Improvement |
| Cup Feet (Self-Aligning) | The cone-shaped design of the stacking feet guides the unit into a secure, perfectly aligned position. This reduces forklift operator time per move by 20-30% and dramatically lowers the risk of dangerous misalignment and potential collapses. |
| Demountable Posts | Enables the high-density nesting for return transport, as mentioned above. It also allows the base to be used as a standard heavy-duty shipping pallet if needed, adding to its versatility. |
| Hot-Dip Galvanized Finish | For outdoor, cold storage, or corrosive environments, this finish provides superior protection. Unlike paint, it forms a metallurgical bond with the steel and offers "sacrificial" protection, preventing rust even if scratched. This extends the asset life from 3-5 years to over 20 years, significantly lowering the Total Cost of Ownership (TCO). |
| Customizable Base and Posts | The system can be adapted to unique challenges. For example, an 8-post design provides full-length support for long, flexible materials like PVC pipes, preventing the bowing and deformation that occurs with standard 4-post racks. |
A stack rack, also known as a post pallet or portable stacking rack, is a steel pallet with removable corner posts or frames. It is designed to safely stack bulk, crushable, or irregularly shaped items by transferring the load through its frame rather than the items themselves, allowing for dense vertical storage without product damage.
The main difference is flexibility and installation. A standard pallet rack is a fixed, static structure bolted to the warehouse floor, requiring dedicated aisles. A stack rack is a modular, mobile unit that requires no installation. It can be moved and reconfigured by a forklift, allowing you to change your warehouse layout on demand to adapt to changing inventory levels.
Industries dealing with non-standard products see the most significant benefits. This includes tire manufacturing and distribution, textile and carpet rolls, agriculture (bulk bags of seed or feed), automotive components, pipe and tubing, and the events/rental industry (stacking chairs and stage equipment).
Yes, when used correctly. They are engineered from high-strength steel (like Q235) and designed with features like self-aligning cup feet to ensure stable stacking. It is crucial to respect the manufacturer's load capacity ratings and follow proper forklift operating procedures to ensure maximum safety.
Their posts are removable. Once removed, the empty bases can be "nested" together, stacking very compactly. This dramatically increases the number of empty units that can fit on a return truck—often 4 to 6 times more than fully assembled racks. This 75-80% reduction in return shipping volume makes reusable packaging systems highly cost-effective.
