Optimization: Warehouse and Pallet Position Analysis

We do more than just sell forklifts. We’ll help you with game-changing solutions for all of your warehouse and material handling challenges.

Our experienced team of Storage and Automated Systems professionals can analyze your warehouse and provide customized solutions to maximize your pallet storage and productivity; and ultimately–your bottom line.

If you’re always asking yourself “How can I maximize my warehouse space? ”, we can help. Here are two examples of the thorough complimentary analysis that we provide to maximize the efficiency of your racking design, equipment selection and overall operation.

Keep in mind that we’ll customize these recommendations to you. We can go as in-depth or as simple as you need. What’s right for your business is up to you. But we’re always here to help.

How To Increase Storage Capacity In Your Warehouse

There are many ways to get more out of your existing space. The right solutions are usually a combination of the right equipment, a smarter layout, and more efficient travel routes. Here at Toyota Material Handling Solutions, we have decades of experience plus the expertise of Toyota engineers to help us figure out how to optimize your space.

Whether you’re trying to save on fuel, fit more pallets into your space, prevent accidents, or prepare for a seasonal influx, we’ll find the right solution you need.

Read our examples below which show a bit of our analysis.

Example 1: You need to store 8,500 pallets and want to know how many square feet of warehouse storage you need

Let’s assume the following:

Length of pallet: 48″
Width of pallet: 40″
Height of pallet with product: 60″
Clear height of warehouse: 24′
Number of pallets you need to store: 8,500
Dock, staging, and offices are not included in the storage calculation

Equipment Model	Aisle Width Requirement	# of Pallets Deep	24' Clear Height of Warehouse	32' Clear Height of Warehouse
4-Wheel Electric Sit-Down Rider	144"	1	123,427 sq. feet	74,056 sq. feet
3-Wheel Side Electric Sit-Down Rider	132"	1	117,406 sq. feet	70,444 sq. feet
Reach Truck	102"	1	102,354 sq. feet	61,413 sq. feet
Articulating Forklift (Aislemaster VNA)	72"	1	87,302 sq. feet	52,381 sq. feet
Double Reach Truck (double deep)	132"	2	84,292 sq. feet	50,575 sq. feet

As you can see in the table above, by using a different lift truck your square footage requirements for the storage of 8,500 pallets will go up or down. Based on the associated aisle width requirement for each lift truck, the number of pallets stored stays the same, but the size of the warehouse needed is larger or smaller.

Solution: By using a Toyota Double Reach Truck, you can store 8,500 pallets in 30% less space than a 4-Wheel Electric Sit-Down Rider.

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Example 2: You have a 126,420 square foot warehouse and need to know how many pallets you can store

Let’s assume the following:

Length of pallet: 48″
Width of pallet: 40″
Height of pallet with product: 60″
Clear height of warehouse: 24′
Width of pallet storage area: 210′
Length of pallet storage area: 602′
Square footage of building: 126,420

Equipment Model	Aisle Width Requirement	# of Pallets Deep	# of Pallets Stored
4-Wheel Electric Sit-Down Ride-	144"	1	8,706
3-Wheel Electric Sit-Down Rider	132"	1	9,153
Reach Truck	102"	1	10,499
Articulating Forklift (Aislemaster VNA)	72"	1	12,309
Double Reach Truck (double deep)	132"	2	12,748

As you can see in the table above, changing the type of lift truck and the associated aisle width requirement, allows you to store more pallets in the same storage footprint.

Solution: By using a Toyota Double Reach Truck versus a 4-Wheel Electric Sit-Down Rider, you can store 46% more pallets.