Live Pallet Racking (FIFO)

FIFO stands for First In, First Out: the first unit load to enter storage is also the first to leave. In logistics, this principle is used to ensure orderly stock rotation, particularly for products with an expiry date, a preferred consumption sequence, or a strict traceability requirement.

In the warehouse, FIFO can be achieved through correct management of storage locations, SKU references, batches, and expiry dates. Where the operation demands it, FIFO flow can also be supported by storage systems that physically separate the loading and unloading points — such as FIFO live pallet racking — enabling a continuous and controlled flow of goods.

It is important to distinguish between the FIFO principle and the storage system: even in solutions not designed specifically for FIFO, correct rotation can be maintained through disciplined location management by reference, batch, and expiry date.

FIFO gravity flow racking is a high-density palletised storage system in which unit loads travel by controlled gravity along roller tracks with a slight incline. Each pallet is loaded at one end of the channel, advances progressively and safely via braking and control elements, and is ready for retrieval at the opposite end.

This configuration enables genuine FIFO management, optimises stock rotation, and increases storage density without requiring the forklift truck to enter the racking structure.

Unlike other compact systems, each pallet retrieved from the discharge face automatically creates a free slot at the loading face, allowing high channel occupancy to be maintained without blocking earlier batches. The trade-off is that the system requires two working aisles — one for loading and one for unloading.

FIFO live racking ensures that the first unit load to enter is the first to leave — a critical requirement in warehouses handling products with an expiry date, a best-before date, or a batch release requirement. By design, the system prevents older stock from being stranded behind newer arrivals, eliminating the need for manual rotation and reducing the risk of expired goods remaining in storage.

This is particularly valuable in food, pharmaceutical, and cosmetics distribution, where regulatory compliance and product quality depend on rigorous stock rotation.

The key difference lies in the stock management logic and the operating method. FIFO live racking uses two separate aisles — one for loading and one for unloading — ensuring genuine first-in, first-out rotation. Push-back racking operates from a single face and uses LIFO logic. Drive-in racking also operates from a single face with LIFO flow, but the forklift truck enters the structure to deposit pallets on support rails, which increases the risk of structural impacts.

For operations where stock rotation is critical, FIFO live racking is the recommended solution. Push-back and drive-in systems are better suited to products where FIFO is not a priority and high density is the primary objective.

The depth, incline, and capacity of the channels depend on variables including pallet dimensions, pallet weight, the specific product being stored, and the overall operational requirements. There is no single standard specification — each channel is designed and calculated individually.

AR Racking selects the appropriate roller track system, incline angle, and braking elements for each project to ensure that pallet movement is smooth, controlled, and safe throughout the full depth of the channel, regardless of load variation.

No. FIFO gravity flow racking operates by gravity alone, thanks to the slight incline of the roller tracks. No motors or electrical power supply are required for the pallet movement itself. The controlled descent is managed entirely by the mechanical braking and retardation elements integrated into the roller track.

This makes the system highly reliable, with minimal maintenance requirements compared with motorised alternatives, and no dependency on electrical power for the movement of goods within the channels.

FIFO live racking can be used with various types of handling equipment, provided the system is designed to accommodate them. Counterbalance forklift trucks and reach trucks are the most common choices for loading and unloading operations at the two separate aisle faces.

The choice of equipment influences the aisle widths, pallet overhang limits, and structural clearances, all of which are factored into the design by AR Racking’s engineering team.

In FIFO live racking, pallet movement is controlled by the combination of the channel incline, the roller track design, and a series of mechanical braking and retardation elements. These elements regulate the speed of descent as each pallet travels from the loading face to the unloading face, preventing excessive acceleration and ensuring a smooth, controlled flow.

Separators and anti-tipping devices can also be integrated to prevent pallets from colliding or overriding each other within the channel.

Yes. FIFO live racking can be integrated into automated environments, though it should be clarified that the pallet movement within the channels is always gravity-driven and does not require automation. What can be automated is the loading and unloading at the aisle faces — for example, by replacing forklift trucks with automated stacker cranes, AGVs, or other robotic handling equipment.

In these configurations, the FIFO live racking structure must be designed to meet the tighter tolerances and interface requirements of the automated equipment.

FIFO live racking is classified as a compact or high-density storage solution for palletised loads. It sits between conventional selective racking — which offers maximum accessibility but lower density — and fully compact systems such as drive-in racking, which maximises density but with more limited selectivity.

Within the compact storage category, it is distinguished by its genuine FIFO operating logic and the physical separation of loading and unloading aisles, making it particularly suitable for perishable goods, strict batch control, or operations where stock rotation is a primary operational requirement.