DRIVE-IN PALLET RACKING

1
Flow of presentation

I. Introduction

II. Application

III. Solution elements

IV. Product Features

V. Summary
2
Flow of presentation

I. Introduction

II. Application

III. Solution elements

IV. Product Features

V. Summary
3
 Pallet Racking Solution

Dense
Non Dense &
Selective Non Selective Selective

Very
Wide Aisle Double deep
Narrow
Aisle

Drive In
Narrow
Aisle
ASRS
Push back

Shuttle
Mobile

Flow 4
 Pallet Racking Solution

Dense
Non Dense &
Selective Non Selective Selective

Very
Wide Aisle Double deep
Narrow
Aisle

Drive In
Narrow
Aisle
ASRS
Push back

Shuttle
Mobile

Flow 5
Drive-in pallet racking
- suitable solution for few SKU varieties & large volume

6
Drive-in pallet racking
- suitable solution for few SKU varieties & large volume

7
Drive-in pallet racking
- suitable solution for few SKU varieties & large volume

8
Drive-in pallet racking
- suitable solution for few SKU varieties & large volume

9
About Drive-In

Drive-in, a pallet storage system for unitized loads

suitable for batch storage, better cubic space utilization
operated by material handling equipments
like Forklift, Reach truck.

10
Flow of presentation

I. Introduction

II. Application

III. Solution elements

IV. Product Features

V. Summary
11
 Applications – Drive-in Racking

BEVERAGES CHEMICAL HEALTH CARE / FMCG

CONSUMER DURABLES PAINT FOOD

and many more 12
Flow of presentation

I. Introduction

II. Application

III. Solution elements

IV. Features

V. Summary
13
Major solution elements
PALLET

MHE

The key is to connect these

elements to ensure they perform
together to achieve the solution
SPACE
objectives 14
Material handling equipments

Reach Truck Forklift Stacker TSP AFLT

15
Material handling equipments

Reach Truck Forklift Stacker TSP AFLT

Reach truck & Fork Lift would be the preferred equipments

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Are stackers Good for a Drive in system?

• Stacker is generally not recommended due to safety of operator

• Manoeuvrability inside the bay is very difficult as no steering

REACH TRUCK STACKER 17

MHE Traverse inside the system

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Pallets

4 way non reversible 4 way non reversible 4 way reversible plastic

wooden plastic

Leg type wooden pallet Collapsible Pallet Leg type pallet

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4 way wooden pallet is ideal for a Drive-in system.
 The space

Various aspects of the warehouse space

 The clear height
 Foot print area
 Material entry/exit points
 Floor height
 Dock design
 Type and strength of the floor
 Auxiliary areas

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The space

U - FLOW STRAIGHT - FLOW

Layout planning to be done inline with the material flow 21

 Cubic space utilization ( indicative)
60%

50%
50%
40% 43% 43% 43%

30%
28% 28% 30%
CSU
20% 23%
18%
10%

0%
WAR

DDPR

PFR
NAR

VNAR

PBR

DRIVE IN

SHUTTLE

MPR
22
 Cubic space utilization ( indicative )
60%

50%
50%
40% 43% 43% 43%

30%
28% 28% 30%
CSU
20% 23%
18%
10%

0%
WAR

DDPR

PFR
NAR

VNAR

PBR

DRIVE IN

SHUTTLE

MPR
23
 Solution building
• The solution to be developed in conjunction with various
elements like MHE, pallet, warehouse building.

• MHE selection & Compatibility with Drive-in

If very essential.

• System to be made compatible with the kind of pallets

being used.

• Seamless material flow to ensure smooth operations

SPACE

• Layout planning to maximize the space utilization and to

reduce any kind of crisscross movement.

24
Flow of presentation

I. Introduction

II. Application

III. Solution elements

IV. Features

V. Summary
25
Product features

I II
Range and Safety elements
Robustness

Stability Design Codes and

Elements Standards
III IV
26
Product features

I II
Range and Safety elements
Robustness

Stability Design Codes and

Elements Standards
III IV
27
 Standard Range
Up to 2000 kg • Load per level 500 kg - 2000 Kg Max

• Height up to : 9000 mm ( depends on MHE)

G + 1 to G + 8

Upto 9 m H
• Levels Upto G+8

1. 2
m
pa t
lle o 1.8
tw
i dt m
h

28
29
 Top bracing channel
Top rear stability beam

Top bracing

Top stability beam Rear stability beam

Aisle warning system

Pallet Stopper

Upright
Safety sign board

Pallet Entry guide

Ground level pallet
stopper

Upright protector

Entry guide rail

& clamps

Pallet rail

Basic elements Row guard

Row connectors
Safety elements Guide rail
Support Bracket 30
Stability elements Base plate
 Basic Elements

Upright

Pallet Entry
guide

Basic elements
Row connectors
Pallet rail
Base plate Support Bracket 31
Frame

• Frames are the vertical load bearing supports

• Vertical uprights and bracings are assembled together to form the

frame.

• Frames are supported by the base plates, which are grouted to the
floor by means foundation bolts.

• Frames are connected back to back & across to form the bay

32
 Uprights
• To offer the most optimized solution, Godrej has a
total of 20 profiles ranging from 90 to 120mm,
available in thickness from 1.6 to 3.15mm in its
portfolio.

• 10 to 12 bends on the uprights are suitably designed

to improve the load bearing capacity.

GXL120 • The slots at 50mm pitch provides a convenient

beam level adjustability.
GX120

GXL110
• Made in machines imported from Europe to ensure
high level of profile accuracy.
GX110

GXL90
• Made from high strength steel having min yield
strength of 355MPa
GX90
Finish : Powder coated
Color : Oxford blue 33
 Uprights – State of the art manufacturing process

• Capable to produce uprights at 24m/min to ensure quick ship.

• Capable to maintain accuracies to the international standards 34
 Uprights – profiles with high levels of precision

Parameter Tolerance

Overall length +/- 2 mm

First slot to last slot

+/- 2 mm
distance

0.5 mm/m subject to

Camber / Bow along
4 mm max on 12 m
length
length

LENGTH CAMBER BOW

FIRST TO LAST SLOT

• Precise manufacturing to meet installation tolerance as per SEMA / FEM 10.2.07 / EN15620 /.
35
 Bracings
• Bracings provide the required rigidity to the
frames.

• Lipped Channel section that connects uprights

to make frames.

• Manufactured in roll forming machines to ensure

uniform profiles and faster delivery.

• Assembled by hexagonal nuts and bolts

Finish : Galvanized
Color : Galvanized 36
 Baseplates
• Base Plates are designed to withstand
compressive force.

• Welded construction bolted to the upright

• High gauge steel (5mm bottom plate and 3.15mm

top channel) to provide adequate rigidity.

• Grouted to the floor by 2 nos of torque type

mechanical anchor bolts

• This can withstand pull-out and shear forces that

TORQUE TYPE MECHANICAL may come up during normal operations.
ANCHOR M12x100

Finish : Powder coated

Color : Bright orange 37
 Bracing cleat
Bracing Cleat • Channel type profile that connects Horizontal
bracing directly to the upright front face.

• Bracing cleats are provided only for three upright

frames.

• Assembled by hexagonal nuts and bolts

Finish : Powder coated

Color : Oxford blue 38
 Row connectors
• Lipped channel with rectangular plates on both
sides to fix with the face of the frame.

• Row Connectors connect back to back Frames

Row Connector and ensure stability of the system.

• Made from roll-formed profiles of 30x30mm C-

channels.

• Assembled by hexagonal nuts and bolts

Finish : Powder coated

Color : Oxford blue 39
 Support Bracket
Support Bracket-LH Support Bracket-RH
• A 4-Bend Formed section that transfers load from
Pallet Rail to the Upright.

• They are hooked on to the upright and bolted at

one location.

• Special lanced design prevents rotation and uplift .

• Available in 3 variants : 75, 100 & 125 mm , to

suit pallet clearances.

• LH & RH pair

• Assembled by hex nuts and bolts

Finish : Powder coated
Color : Oxford blue 40
 Pallet Rail
• Pallet Rail is to rest the pallet in deep

• The resting surface of 84mm width provides larger

seating area for the pallet.
Pallet Rail
• Slanting face of the pallet rail helps MHE operator
to place the pallet easily with-in the pallet rails

• Assembled by hexagonal Bolts and Nuts

• The pallet rails are connected along the depth in

level with no interference with pallet placement

84mm

Finish : Galvanized
Color : Galvanized 41
 Pallet Entry Guide
• A Moulded and rugged component.

• Visual guide to MHE operator to align the pallet at

entry.

• Mounted on the Support bracket of the front

Pallet Entry Guide upright of each bay in all levels for safe entry.

• Made of Nylon with glass-fibre

Finish : Moulded – Nylon Type

Color : Yellow 42
Product features

I II
Range and Safety elements
Robustness

Stability Design Codes and

Elements Standards
III IV
43
 Safety Elements
Pallet Stopper

Aisle warning
system

Safety sign board

Upright
protector

Ground level pallet

Entry guide rail stopper
& clamps

Row guard
Safety elements Guide rail
44
 Pallet stopper Optional

• This Unique stopper provided at all levels except

ground at the end of bay.

• Acts as a back-stopper, preventing a pallet over-

hang beyond rail limit.

• The height shall be 164mm

• Assembled by hex Bolts and Nuts

Finish : Powder Coated

Color : Yellow 45
 Ground Level Pallet Stopper Optional

• This stopper is provided at the ground level at the

end of bay

• Acts as a back-stopper preventing a pallet over-

hang beyond rack bay limit

• Strong angle profile of 10 mm thick with gusset.

Ground Level
Pallet stopper

Finish : Powder Coated

Color : Yellow 46
 Guide Rail & Clamps Optional

• The Main guide rail is an ISA section mounted on

support clamps.

• MHE fitted with rollers can manoeuvre inside the

bay safely

• The rail support clamps are grouted at a pitch to

Stopper mounted on add rigidity to the structure.
Guide rail
the guide rail end & clamps
• Impact on rails are transferred to ground & the rails
are independent from storage system.

• MHE with roller attachment is must to benefit the

purpose of rails

• Roller details of MHE is must to decide rail height.

Finish : Powder Coated

Color : Yellow 47
 Entry Guide Rail Optional

• Entry guide rail to guide MHE into the bay.

• Impact on these members will not affect the

stability of the system, as it’s independent from
the system.
124/ 75 mm Height rails
• The profile such that an entry angle of 15° is
maintained allowing a smooth entry of MHE into
the system.

• Grouted/ anchored to the floor with Grouting Bolts

• MHE with roller attachment is must to benefit the

purpose of rails

Finish : Powder Coated

Color : Yellow 48
 Aisle Warning System Optional

• A Safety Equipment with motion sensors to detect

presence of MHE in the bay.

• LED glows when the MHE reaches the second

pallet position in the bay.

• A Pyro-electric infrared motion sensor (PIR) is

activated when the forklift enters the aisle, which
in turn causes the LED to flash.
General Features:
• It can be directly mounted onto the upright
• The sensor is de-activated only when the forklift is
• Four PIR sensors are used to detect MHE on
out of the aisle.
both side of the bay
• No need of any wiring to an electrical system
• Fully battery operated
• Warning with LED flashing
49
• Maximum LED flashing time is 5 minutes
 Safety Row guards Optional
• Capable to take the impact load of 400Joule as
per SEMA/FEM/EN15512.

• Rugged construction from 60x60mm square tube

with an intermediate 57mm dia pipe.

• Gussets to prevent the MHE running over the

grouting bolt.
60x Safety Row
60m Guard
mt • Two piece design for a double face rack to
hick
400mm

Squ
are
Tub improve the strength and enable easy
e
replacement.

• Yellow-black combination to improve the visibility.

ET
Finish : Powder Coated
USS Color : Yellow 50
G
 Upright Protectors Optional

• The Upright Protectors of 500mm Height, fixed in

front of all aisle facing upright

• Safe entry of MHEs

• Avoids any accidental direct hit on uprights while

entry.

Upright Protector

Finish : Plastic
Color : Flouro Yellow 51
Safety sign boards
Safety Sign Boards

• These signage are for the safety of warehouse personnel

and to enable longer storage life.

• Size – 600 x 800mm

• All load warning notices are designed and installed as per

EN 15635:2008

52
Product features

I II
Range and Safety elements
Robustness

Stability Design Codes and

Elements Standards
III IV
53
 Stability Elements
Top rear stability beam
Top bracing
channel

Top bracing

Rear stability beam

Top stability
beam

Stability elements 54
 Top stability Beam
• The box beams are fixed to the top end of
each frame and bolted to the uprights.

• It ensures system stability by integrating

each bay as a single block.

• Made by roll forming process to ensure

adequate strength.

Top Stability Beam Top Bracing

• Assembled by hexagonal nuts and bolts

Finish : Powder coated

Color : Bright orange 55
 Rear stability Beam Optional

• These box beams are fixed to the rear of each

frame and bolted to the uprights.

• It ensures system stability by integrating each bay

as a single block.

• Made by roll forming process to ensure adequate

Rear Stability Beam Rear Bracing
strength.

• Assembled by hexagonal nuts and bolts)

Finish : Powder coated

Color : Bright orange 56
 Top Bracing Channel

• To interconnect the Frames.

• Suitable for varying upright sections.

• Connected to upright top to add stability along the

depth
Top Bracing
Channel
• For longer depth, joining pieces are used along

• Assembled by hex nuts & bolts.

Finish : Powder coated

Color : Oxford blue 57
Product features

I II
Range and Safety elements
Robustness

Stability Design Codes and

Elements Standards
III IV
58
 Design codes and standards
Codes / Standards

Raw Material Design - General Design - Racking Erection tolerances

• BS: 5950 • SEMA • FEM 10.2.07 STANDARD

• IS: 5986/2062
ON
• Equivalent to EN 10025
• IS: 800/801 • FEM 10.2.07 • FEM 10.2.07 REQUEST
JIS 3101 / ASTM: A 572
• AISI / AISC
• EN1993-1-3

• Godrej Drive-in is designed as per BS 5950 Part 5 and SEMA code

of practice.

• In house design and testing capability to comply any international

code

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Seismic resistant design Optional

• Godrej has the expertise and experience in designing and

installing seismic resistant racks for low and high seismic
zones.

• Capability to design as per Indian and international codes

like IS1893, FEM10.2.08, ANSI MH 16.1 (RMI), IBC/UBC

• Seismic design backed by international seismic experts

60
Product features

I II
Range and Safety elements
Robustness

Stability Design Codes and

Elements Standards
III IV
61
Flow of presentation

I. Introduction

II. Application

III. Solution elements

IV. Features

62
 Summary
• Godrej Drive in Pallet Racking : to suit wide range of applications.

• Capable to build solutions to meet your requirements.

• Wide range of profiles to suit varying load requirements

• Modular & scalable system

• Safety & Stability Elements to support your operation

• International standards & features

• Product recognized internationally

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