Warehouse Storage: How To Prevent Falling Items

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Warehouse Storage: How To Prevent Falling Items

Warehouse Storage: How To Prevent Falling Items

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Warehouse storage helps companies arrange their products and sort them according to category, name, or kind. Some pile it side by side, others stack them on top of each other. However, one downside of stacking them together is the possibility of falling items from the shelves.

A lot of factors affect why products fall down. Products fall when natural calamities occur, like earthquake, hurricanes, or even machine mistakes. Other times, they fall just because of gravity.

How to stop the drop through warehouse storage?

One of the things that warehouse managers need to avoid is using pallet racks to store their products. Pallet racks stand tall at 30 feet and people use them to stack products. However, if the products were not stacked properly, they can fall, leading to injuries and catastrophe in the warehouse.

Follow these steps to prevent falling items.

Think of falling items when organizing products

Racks made of different materials possess different strength levels. Some racks are built for heavy products yet some are for carrying only lighter materials. To save on expenses, make sure to stack items depending on the strength of the racks themselves.

Make sure to check the vertical space

When using racks, check the overall height of the warehouse and the beam spacing of the rack. Remember that the recommended spacing is at least 10 inches, so make sure to leave drivers a lot of space for them to maneuver the pallets. Remember that when changes in inventory happen, don’t go beyond the 10 inches allowance. Otherwise, inventory may fall.

Illuminate the entire warehouse

If the warehouse lacks lighting, it contributes to errors that cause falling items. When installing lighting inside the warehouse, remember to put it on the ceiling with bright bulbs. Other warehouses use solar power to save energy. A well-lit warehouse prevents errors and damage to inventory. This also avoids accidents to the staff during loading and unloading.

Load the racks evenly

Some racks use supports that may change the balance of the rack. When staff fails to balance the weight distribution of the racks, the items will fall. This leads to injuries and losses for the company.

Store the heaviest at the bottom or on the floor

One of the most common things about storing is to put the heaviest items at the bottom of the rack or on the floor. If the racks prove to be sturdy enough, remember to follow the recommended weight per level to avoid mishaps.

Proper care for the racks

Loading and unloading across racks affects the stability of the rack itself. Some encounter accidents and neglect to send a report to their seniors. The lack of information about the damage means other staff might continue using those racks that damage the products.

If the warehouse is located in an  earthquake prone area, remember to stack the items low to avoid damage. Check the material of the racks to see if they are sturdy enough to withstand earthquakes.

Install protective wires for the racks

Some warehouse staff install wires or safety nets as a precaution for falling objects, especially for high racks. Warehousemen may choose between safety nets or wire mesh panels to safeguard items from falling.

Safety nets are more flexible and catch cartons easily, especially ones put in higher positions. These safety nets prevent boxes from falling as it gently pushes the cartons in place. However, for wire mesh panels, these stop the items from falling and do not push them back. They hold them in place until staff pick them up or put them back onto the racks. Not only that, but these nets prevent injuries to the staff in case of falling.

Train for improvement and better performance

Every company undergoes trainings and seminars to improve their performance. The technology used in different companies improves as time passes. When the company adapts new technology, they require the staff to undergo training in order to fully comprehend on how to operate the machines.


Reno Forklift provides different services, especially material handling needs. These tips aim to inform companies and other business involved in inventory management on how to prevent falling items in the warehouse. Contact Reno Forklift for your warehouse handling needs!

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