Kanallager

What is a channel storage system?

A channel storage system is a multi-deep pallet storage system in which load units are stored not side by side, but one behind the other in channels. The channels typically consist of rails or roller tracks along which pallets are pushed in and out. The goal is to achieve a significantly higher storage density than with conventional pallet racking, as driving aisles are eliminated. The system is particularly suitable for items with high pallet throughput and low product variety — in other words, wherever many pallets per SKU are moved.

Operating principle and access methods

The access method depends on whether the channel is served from one or both sides. With drive-in racking — the simplest variant — the forklift drives directly into the channel and pushes pallets from the back to the front. This creates a LIFO sequence (Last In, First Out), as the most recently stored pallet is always retrieved first. This variant is cost-effective but carries a higher risk of impact damage to the racking structure.

Flow-through racking, by contrast, operates on the FIFO principle (First In, First Out): pallets are loaded on one side and travel by gravity or conveyor technology to the retrieval side on the opposite end. This design is more complex to construct but is necessary when batch integrity or best-before dates require a strict sequence.

Satellite storage systems represent a more technically advanced form: an automatically controlled satellite vehicle handles the storing and retrieval within the channel, while the forklift is only positioned at the channel entrance. This reduces impact damage and increases throughput speed.

• Drive-in racking: LIFO, cost-effective, higher impact risk
• Flow-through racking: FIFO, more expensive, for batch-sensitive items
• Satellite storage: automated channel operation, high throughput performance

What to consider when selecting a system

Channel storage is not a universal solution. Before planning it, you should verify that your product range actually provides a sufficient number of identical pallets per item. Channels are generally dedicated to a single SKU, which means that empty channel sections behind the front pallet are wasted if replenishment does not arrive regularly. This effect is known as honeycombing; it significantly reduces the efficiency gain compared to conventional racking.

The choice between LIFO and FIFO is also important, and should be made not solely on the basis of storage density but according to the requirements of your products: for food, pharmaceutical products, or other batch-sensitive goods, FIFO is generally required by law or quality standards. For homogeneous industrial goods without an expiry date, LIFO may be sufficient.

Safety and maintenance aspects also play a role. Drive-in racking is subject to increased impact risk and must be regularly inspected for deformation. Applicable standards for racking systems must be observed; specific inspection intervals and documentation requirements should be clarified with the manufacturer and a qualified inspector. Forklift technology must be matched to the channel depth and load capacities — not every forklift is suitable for deep channels.