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In addition, we also provide solution packages that are fully tailored to your warehouse shelving installation needs.
VI
OPTIMIZING FIFO, HACCP COMPLIANCE & FOOD WAREHOUSE RACKING SAFETY 2026
In the food and beverage (F&B) industry, warehouse logistics is more than a physical storage function. It is a critical link that directly affects product quality, inventory shelf life, supply chain efficiency, and operating margins.
From agri-food and seafood processing plants and frozen food warehouses to major FMCG companies and modern 3PL distribution centers, warehouse planning revolves around several core challenges:
- Strict shelf-life control through FIFO/FEFO principles to minimize product expiry and write-offs.
- Maximizing pallet storage density to optimize operating costs per pallet position.
- Meeting stringent food safety and hygiene requirements, including HACCP, ISO 22000, and FSSC 22000.
- Maintaining structural durability in demanding operating environments, particularly deep-freeze cold storage facilities.
- Complying with applicable fire safety and fire protection requirements, including the latest relevant technical standards such as TCVN 14496:2025.
Understanding these industry-specific challenges, Hoa Long Mechanical (HLM) provides specialized F&B warehouse racking solutions based on the engineering philosophy:
Why Do Food Warehouses Require Specialized Design?
Unlike general industrial warehouses or conventional component storage facilities, food warehouses are subject to significant biological, chemical, and temperature-related challenges:
- Product shelf life
- Storage temperature
- Humidity
- Pallet storage density
- Inbound and outbound handling speed
- Food safety
- Fire safety and fire protection standards
- Batch/Lot control procedures
…all directly affect the design and configuration of the warehouse racking system. An improperly designed warehouse layout can lead to:
- Localized forklift traffic congestion (Peak-hour bottlenecks)
- Condensation buildup causing rust, corrosion, and mold growth
- Obstructed inventory visibility -> FEFO/FIFO date errors – Mass stock write-offs
- Failed Fire Safety (PCCC) & HACCP audits – Operational suspension and costly retrofitting
Every design decision-from steel thickness and surface coating (such as antimicrobial powder coating or hot-dip galvanizing), to beam elevation and forklift aisle width-must be determined based on actual site-specific technical parameters, rather than relying on standardized formulas or one-size-fits-all assumptions.
What Standards Should F&B Warehouse Racking Meet in 2026?
Common Challenges
Below are some of the most common challenges associated with F&B warehouse racking systems (food and beverage storage racking).
Date-Based Inventory Management
The food industry requires strict control of product expiration dates and production batches. If the warehouse layout is not properly optimized for FIFO/FEFO inventory rotation, products can remain in storage for too long, increasing the risk of expiry, inventory loss, and write-offs.
Cold Storage Conditions Affect Racking Service Life
Deep-freeze temperatures and high humidity can cause condensation, leading to corrosion of rack uprights, beams, and components if suitable materials and protective finishes are not used.
High SKU Diversity - High-Speed Picking
The FMCG and packaged food industries typically handle a large number of SKUs, requiring continuous inbound and outbound operations and high-speed picking.
Pressure to Optimize Warehouse Space
Cold storage operating costs are high. Businesses need to maximize pallet positions while maintaining safe and efficient warehouse operations.
Increasingly Stringent Fire Safety Requirements
New requirements for sprinkler systems, smoke ventilation, and required safety clearances are directly influencing warehouse layout design.
Food & Beverage Industry Warehouse Racking
Food & Beverage (F&B) businesses need to be well equipped to handle increasingly diversified product portfolios, with new product categories emerging every day-from ready-to-eat meals, organic and diet products, and low-sugar options to soft drinks and spirits. At the same time, store orders are becoming smaller and more frequent, creating additional pressure on warehouse operations.
In recent years, regulatory and product safety requirements have become increasingly stringent. Supply chain models such as “Farm to Fork” and “Farm to Table” have also increased traceability and compliance requirements, creating additional challenges for food manufacturers and distributors.
We understand the operational challenges facing today’s F&B industry and provide tailored warehouse racking solutions designed to improve efficiency and productivity while helping businesses deliver fresh products to consumers as quickly as possible.
Call NowTypical Solutions:
- Automated solutions for high-density pallet storage
- Conveyor systems for material movement between warehouse zones
- AGV systems for automated material handling
- Temperature-controlled storage for chilled and frozen environments
- Order-picking systems for retail stores and e-commerce operations
- Mixed-case picking, layer picking, and piece picking
- Warehouse Management Systems (WMS) and warehouse control software
VNA Racking, Shuttle Racking, Pallet Flow Racking, and more
Quickly Calculate F&B Warehouse Storage Capacity
Compare the Storage Efficiency of Conventional Racking with HLM Shuttle Racking for F&B Warehouses
Warehouse Area
1,000 m²
1,000 m²
Warehouse Height
8 m
8 m
Inventory Flow Method
FIFO (First In, First Out)
LIFO (Last In, First Out)
Traditional Selective Racking
560
Pallet Positions
- Wide Forklift Aisles
- Medium Storage Density
- Higher Space Requirement for Operations
Optimized for F&B Warehouses
HLM Shuttle Racking
980
Pallet Positions
75% Increase in Storage Capacity
- Optimized for Cold Storage
- Reduced Aisle Space Requirements
- FIFO-Compatible for Food Storage
Get a Free Optimized Warehouse Layout
HLM’s engineering team will recommend a suitable warehouse racking solution tailored to your food & F&B operations.
Formula Explanation:
Storage Capacity = (Warehouse Area × Storage Height × Density Factor) / Operating Space Factor
Racking Systems Suitable for F&B WarehousesAll Warehouse Racking Systems
01
Pallet Flow Rack
Solution No. 1: Designed to support strict FIFO (First In, First Out) inventory rotation, helping minimize the risk of products reaching their expiration date.
02
Drive-In Racking
Maximize cold storage cost efficiency by increasing storage density for large volumes of homogeneous products. This approach helps make better use of refrigerated space and can reduce cooling costs per pallet position.
03
Radio Shuttle
Semi-Automated Solution: Shuttle robots handle pallet movement, reducing the need for forklifts to travel deep into racking lanes.
It is also recommended to use galvanized or powder-coated steel pallets instead of wooden or plastic pallets to help reduce the risk of mold and improve durability in cold storage environments.
This approach helps address operational safety and handling efficiency challenges in deep-freeze warehouses.
HLM Recommended Food Warehouse Racking System Selection Matrix
To help businesses develop a clearer investment budget, HLM has developed the following technical solution matrix:
| Specific Operational Requirements | Optimal Racking Solution | Storage Density | Inbound & Outbound Handling Speed | FEFO/FIFO Management Capability |
| Highly Diverse SKUs, Low Pallet Volume per SKU | Selective Racking | Medium | Very Fast | Manual / WMS-Assisted |
| Kho lạnh âm sâu, hàng đồng nhất lượng lớn | Drive-In Rack | Rất cao | Trung bình | Kém (Thiên về LIFO) |
| Extremely Short Shelf Life, Strict FIFO Requirements | Pallet Flow Racking | High | Very Fast | Mechanical Automation |
| Large-Scale Production/Distribution Warehouse, Long-Term OpEx Optimization | Radio Shuttle Racking | Ultra-High | Ultra-Fast | Semi-Automated |
| Combination of Low-Level Piece Picking & High-Level Pallet Storage | Selective + Mezzanine | Space-Optimized | Fast | Flexible |
Technical Factors in Food Warehouse Racking Design
When developing the warehouse layout for a modern F&B facility, HLM’s solution engineering team follows a strict set of technical control parameters to ensure the racking system is properly designed for actual operating conditions:
1. Temperature and Corrosion-Resistant Materials
- Chilled Storage (2°C–8°C) & Deep-Freeze Storage (-18°C to -25°C): Condensation is one of the most significant factors contributing to accelerated corrosion of steel structures in cold storage environments.
- Recommendation: Use high-strength cold-rolled steel with a high-adhesion antimicrobial powder-coated finish, or apply full hot-dip galvanizing to base components and bracing members located close to the floor to help protect against corrosion and mold growth and support applicable HACCP requirements.
For deep-freeze cold storage, wooden pallets are generally not recommended. Instead, consider galvanized steel pallets or industrial-grade plastic pallets specifically suited to low-temperature operating conditions.
2. Aisle Geometry and Floor Load Capacity
- Aisle Width: Must be precisely matched to the actual forklift model and its required turning radius. For example, approximately 2.8 m for a reach truck and 3.4 m for a counterbalance forklift, subject to the specific equipment specifications and operating conditions.
- Floor Load Capacity: The food warehouse floor must be structurally designed and verified to withstand localized static loads beneath rack uprights of ≥5 tonnes per upright, as well as dynamic loads generated by continuous forklift traffic at operating speed. Proper floor design helps minimize settlement and maintain the stability and alignment of the racking system.
3. Integration of Fire Safety & Fire Protection Standards
For food warehouse systems where the storage height on racking exceeds 5.5 m and extends up to 25 m, HLM’s racking design incorporates the applicable requirements of TCVN 14496:2025.
HLM’s warehouse layout drawings maintain required longitudinal and transverse safety clearances between pallets, helping accommodate fire protection provisions, inspection access, and safe warehouse operations.
Common Mistakes
- Insufficient Capacity for Future Growth: The warehouse can become overcrowded within the first year of operation when future SKU expansion and additional storage requirements are not considered during the initial design.
- Choosing the Wrong Racking System: Installing Drive-In Racking in a warehouse with hundreds of highly variable SKUs can make stock retrieval more difficult, increase product handling, and create serious forklift congestion.
- Ignoring Thermal Effects on Materials: Racking design for temperatures down to -25°C should account for material properties and temperature-related dimensional changes. Inadequate consideration of these factors can increase stress on mechanical connections and components.
- Forklift Aisles That Are Too Narrow: Insufficient aisle width can reduce handling efficiency and increase the risk of forklift impacts to rack uprights, potentially affecting racking safety and structural integrity.
- Overlapping Inbound and Outbound Flows: Poor separation of inbound and outbound traffic can increase the risk of cross-contamination between raw materials and finished products and may conflict with applicable food-safety process requirements.
HLM’s Accurate F&B Warehouse Racking Project Design Process
To ensure that every installed racking system operates as a fully integrated system, HLM follows a rigorous five-step design process:
- Operational Survey ── Data collection on SKUs, Pallets, Temperature profiles, and Forklift specifications
- Layout Design & Analysis ── 2D/3D drawing drafting, static & dynamic load simulation, Fire Safety (PCCC) clearance compliance, one-way material flow mapping, and FIFO/FEFO stream optimization.
- Manufacturing & Installation ── Fabrication of racking components, protective coating application, and on-site assembly for F&B racking systems.
- Testing & Inspection ── Structural load testing and operational trials prior to handover
- Bàn giao và bảo hành ──> Sau khi bàn giao, HLM sẽ có chế độ bảo trì , bảo hành phù hợp với từng hệ thống kệ FnB
Featured F&B Customers & Projects
MINH PHU
Customer: Minh Phu Seafood, Song Hau Industrial Park, Hau Giang Province
Products & Services:
Mezzanine Floor combined with Selective Racking
- Benefits:
Efficient warehouse space utilization
- Effective FIFO/FEFO inventory management
Faster inbound and outbound handling
Completion: January 2024
LUONG QUOI
Customer: Luong Quoi, An Hiep Industrial Park, Ben Tre Province
Products & Services:
Shuttle Racking and Mezzanine Floor
- Benefits:
Maximized warehouse utilization and operational efficiency
- Improved inbound and outbound handling performance
Increased storage capacity and overall warehouse productivity
Completion: 2020
Why Do Leading F&B Companies Choose HLM?
- Deep Understanding of Logistics Operations: HLM does not simply supply steel racking. We provide warehouse design solutions based on the actual movement and flow of goods throughout the facility.
- In-House Manufacturing Capability: HLM’s large-scale mechanical manufacturing facility maintains strict control over the production process, from incoming steel material quality to the thickness and finish of protective coatings selected for food warehouse environments.
- Integrated Fire Protection & Food Safety Considerations: HLM’s engineering team has practical project experience and understands the applicable requirements of TCVN 14496:2025, helping ensure that warehouse racking layouts are coordinated with fire protection and relevant food-safety requirements from the design stage.
HLM Infrastructure & Service Coverage: From Ho Chi Minh City, Binh Duong, Dong Nai, and Long An to key Mekong Delta provinces such as Hau Giang and Ben Tre, HLM is ready to serve customers across major industrial parks throughout Southern Vietnam.
Get Free Layout Consultation & Preliminary Site Survey
Is your enterprise planning to build a new cold storage facility or seeking to upgrade your current F&B warehouse racking system to prevent stock write-offs due to expired products and optimize operating costs? Leave your information or contact the solution engineering team at Hoa Long Mechanical (HLM) today. We are ready to support:
🎁 100% Free: On-site survey services and warehouse footprint measurements.
📈 Preliminary Design: 2D/3D layout drawings optimizing forklift operating aisles and accurately calculating total pallet capacity.
🚒 Integrated Consultation: Racking structural engineering fully compatible with automatic fire protection systems compliant with TCVN 14496:2025 standards.
*** Don’t let initial layout errors cost billions of VND in annual operating and modification expenses.
FAQs
Which Type of Racking Is Best for a Food Warehouse?
The appropriate racking system depends on the warehouse operating model. For F&B and FMCG warehouses with a high number of SKUs, Selective Racking is often suitable. For high-density cold storage, Shuttle Racking or Drive-In Racking can be considered.
Does Cold Storage Require Specialized Racking?
Yes. Cold storage racking requires corrosion-resistant materials, structural components suitable for low-temperature environments, and a design adapted to operations in deep-freeze conditions. When cold storage is used for food, pharmaceuticals, or vaccines, the racking system should also meet applicable safety, hygiene, and storage requirements.
How Can You Optimize FIFO in a Food Warehouse?
Pallet Flow Racking, Selective Racking, or Shuttle Racking can be used depending on the inbound/outbound handling speed and type of goods. For fast and professional support, please contact Hoa Long Mechanical (HLM) toda
Is Fire Protection Planning Required When Designing Warehouse Racking?
Yes. A modern warehouse layout should consider multiple factors simultaneously, including:
- Sprinkler systems
- Smoke ventilation gaps
- Storage height
- Required safety clearances
- Material handling and traffic flow
These factors should be coordinated during the design stage to help reduce operational risks and support safe, efficient warehouse operations.
