System 03 · The cold storage workhorse
Drive-in racking: maximum density for few SKUs, high volume.
In drive-in racking the forklift drives into the structure itself. Pallets rest on continuous rails on both sides of the lane rather than on beams across the front, so lanes can run four to ten or more pallets deep with no aisle between them. It delivers the highest density available without moving parts, which is why it dominates Indonesian cold storage — and why it demands the most protection.
In brief
In drive-in racking the forklift drives into the structure and pallets rest on continuous rails, so lanes run four to ten or more pallets deep with no aisle between them. It gives the highest density available without moving parts, and it dominates Indonesian cold storage.
- Floor utilisation of 60–80%, against 30–40% for selective racking, because the aisles between lanes disappear.
- Last-in-first-out for drive-in; open both ends for drive-through and you get first-in-first-out at the cost of more floor and steel.
- The forklift works inside the structure, so entry guards, column protection and a same-day damage rule are part of the design.
- Specify hot-dip galvanised frames, rails, brackets and guards for chilled and frozen rooms — not frames alone.
01 — How it differs structurally
Rails, not beams, carry the load
This is a different structure from selective racking, not a variation of it. Understanding that difference explains every design rule that follows.
Pallets sit on continuous rails running the depth of the lane, supported by brackets on the uprights. The pallet itself becomes part of the load path, so pallet quality and consistency matter far more than in selective racking.
The lane must be wide enough for the truck, the load and a working tolerance on each side. Too tight and you buy daily impact damage; too generous and you give away the density you are paying for.
Because there is no front beam tying frames together, drive-in structures rely on top ties, back bracing and a rigid portal at the lane entry. This is where cheap drive-in racking is quietly under-built.
The forklift operates inside the structure, so impact is not a risk but a certainty over time. Entry guards and column protection are part of the design, not an optional line item.
02 — When it is the right answer
Few SKUs, deep stock, high volume
Frozen and chilled stores
Refrigerated volume is the most expensive space in any Indonesian warehouse. Removing aisles cuts the volume you have to keep cold, and the energy saving often outweighs the racking cost within a few seasons.
Beverage and bottled water
Few SKUs, enormous pallet counts, predictable production runs. Lanes can be assigned by production batch, which keeps rotation manageable despite the LIFO nature.
Bulk commodities
Rice, sugar, flour, fertiliser, animal feed and resins: homogeneous goods held deep, where selectivity has little operational value.
Multi-client 3PL
Many SKUs at low depth means half-empty lanes. Density on the drawing, wasted space in reality.
Strict date rotation
Drive-in is LIFO. If every pallet must move in date order, use drive-through, pallet flow, or a shuttle system configured for FIFO.
Poor pallet quality
Loads sit on rails, spanning between two lines of support. Broken stringers and inconsistent pallets are dangerous here in a way they are not on a decked selective bay.
03 — Design parameters
The numbers that shape a drive-in block
| Parameter | Typical range | What drives it |
|---|---|---|
| Lane depth | 4–10+ pallets | Pallets per SKU and daily throughput; deeper lanes cut cost per position but slow retrieval |
| Lanes per block | 2–20+ | Number of SKUs held simultaneously — one SKU per lane is the rule that keeps rotation sane |
| Rail levels | 2–5 | Clear height, load height and truck lift capacity at height |
| Load per pallet | Up to 1,500 kg typical | Rail section and bracket spacing follow the actual unit load |
| Finish | Powder coating or HDG | Hot-dip galvanising for chilled, frozen and washdown environments |
Lane depth is the main commercial lever. Going from four to eight pallets deep roughly halves the number of entry portals per pallet stored, but doubles the average travel inside the lane.
- One SKU per lane wherever possible — mixed lanes are where drive-in efficiency goes to die.
- Plan for lanes to sit around 85% full on average; a permanently full drive-in block has no room to work.
- Specify galvanised rails, brackets and guards for cold stores, not just galvanised frames.
- Write a same-day damage reporting rule into your SOP before the first pallet goes in.
04 — Protection and operation
Impact management is the whole game
Every serious drive-in failure traces back to accumulated forklift damage that nobody logged. Design the protection in, then run the discipline.
- 01
Guard the entry
Heavy floor-fixed guards at every lane entry upright, plus guide rails on the lane floor where the truck runs. These absorb the routine contact so the structure does not.
- 02
Train for the lane, not the aisle
Entering a lane is a different skill from aisle work: slower speed, mast fully lowered, no steering correction under load. Include it in operator induction, especially in cold stores where visibility is poor.
- 03
Inspect weekly, report same day
Any dented, bent or paint-fractured upright is unloaded and reported the day it is found. A damaged column has already lost capacity; the pallets above it are what make that dangerous.
- 04
Replace, do not straighten
Bent uprights are replaced with new components, never heated and pulled back. We hold replacement uprights, rails and brackets for the systems we supply.
Questions buyers ask
Frequently asked questions
How much space does drive-in racking actually save?
Floor utilisation typically rises to 60–80%, against 30–40% for selective racking, because the aisles between lanes disappear. The exact figure depends on lane depth, building shape and how consistently one SKU fills one lane.
Is drive-in racking suitable for cold storage?
It is the most common choice for cold storage in Indonesia, because it delivers high density at moderate investment. Specify hot-dip galvanised frames, rails, brackets and guards — condensation from temperature cycling attacks coated cut edges and welds first.
What is the difference between drive-in and drive-through?
Drive-in is closed at the back, loaded and unloaded from one side, and works last-in-first-out. Drive-through is open at both ends for first-in-first-out, but it needs aisles on both sides and more steel for stability.
Can I mix SKUs in one lane?
You can, but you should not. A mixed lane forces you to move pallets you do not want in order to reach the one you do, which cancels most of the operational benefit. Size lane depth so that one SKU comfortably fills one lane.
Why is drive-in racking more expensive per bay than selective?
More steel per pallet position in rails, brackets, top ties and bracing, plus substantial guarding. Cost per pallet position is often still competitive because you store far more pallets in the same building.
What lead time should I expect?
Longer than selective racking — plan on four to six weeks of fabrication after drawing approval, and longer again if hot-dip galvanising is specified, since galvanising is an additional external process.
Talk to engineering, not a call centre
Cold store, beverage plant or bulk commodity? Send the pallet count.
We design the lane depth, rail levels and lane count around your daily throughput, then quote fabrication, delivery and installation as one scope.