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Packaging warehouses do not necessarily require extremely fast inbound and outbound handling, but their racking systems must withstand very high and continuous loads. The characteristics of packaging materials place significant demands on warehouse racking systems:
- Extremely heavy carton pallets, which can cause excessive beam deflection.
- Large-diameter paper rolls with long cores, requiring specialized storage methods.
- PE and PP films and other flexible materials stored for long periods, requiring maximum storage density.
- Modern warehouses with clear heights of 10–15 m or more that may not be fully utilizing their available vertical space.
Packaging businesses do not need standard racking configurations taken directly from a commercial catalogue. What you need is a warehouse racking system engineered with accurate structural and load calculations, designed for long-term stability and safe operation under demanding conditions.
– Hoa Long Mechanical
Challenges in Packaging Warehouse Storage & Operations
Vietnam’s packaging industry-particularly in major industrial hubs such as Binh Duong, Dong Nai, Long An, Bac Ninh, and Hai Phong-handles a highly diverse range of products, including carton packaging, kraft paper packaging, PP/PE flexible films, paper tubes, industrial paper cores, and finished jumbo bags.
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Extremely High Pallet Loads
A pallet of finished carton products or raw paper rolls can weigh anywhere from 800 kg to more than 2,500 kg. If the racking supplier incorrectly calculates the steel load-bearing capacity or uses undersized steel sections, beam deflection and column-frame deformation may occur within just a few months, potentially creating serious safety risks for warehouse personnel.
Bulky & Variable Load Dimensions
The dimensions of paper rolls and carton boxes vary depending on customer orders. This requires a racking system with appropriate storage-level heights, accurate forklift clearances, and heavy-duty load-bearing beams.
Ideal for Long-Term Planned Storage
Due to the nature of large-batch, make-to-stock production, inventory turnover is generally not the primary priority. Instead, businesses focus on maximizing storage capacity, minimizing aisle space, and optimizing operating costs per square meter.
Common Mistakes When Designing a Packaging Warehouse Racking Layout
- Wasting Available Warehouse Height
Warehouses are often built with clear heights of 12–15 m, but storage is limited to floor-level stacking or low-level static racking below 6 m. This can result in significant underutilization of the warehouse’s available vertical space. - Choosing the Wrong Steel Grade & Load Standards
Using low-cost racking without appropriate structural calculations can lead to beam fatigue, excessive deflection, and insufficient load capacity. It may also limit the ability to upgrade the racking system when the business changes its product mix or storage requirements. - Overreliance on Traditional Wooden Pallets
Paper and packaging warehouses often contain significant amounts of paper dust and may experience moisture condensation. Wooden pallets can deteriorate, develop mold or insect damage, and deform under heavy loads, resulting in recurring replacement costs and increased risks when storing goods at height. - Placing raw paper rolls directly on the warehouse floor can cause roll deformation or damage to incoming raw materials, make forklift handling more difficult, and unnecessarily consume valuable floor space.
HLM Designs Racking Solutions Based on Each Type of Packaging Product
HLM solution engineers provide a detailed analysis of five optimized racking systems for the packaging industry.
Selective Racking System
Ideal Applications: Warehouses storing carton pallets in various sizes, finished flexible packaging pallets, and high-SKU warehouses.
Technical Advantages: 100% direct pallet accessibility, flexible adjustment of beam-level spacing to accommodate different finished-pallet heights, and easy installation of additional support bars to enhance load stability and operational safety.
Double Deep Racking System
Ideal Applications: Finished packaging warehouses with a moderate number of SKUs but high pallet volumes per SKU, particularly for products stored for extended periods.
Technical Advantages: Configured by installing two rows of Selective Racking back-to-back, reducing forklift aisle space by up to 50% and increasing storage density by approximately 30–40% compared with conventional static racking.
Drive-In Racking System
Ideal Applications: A high-density storage solution for large carton packaging manufacturing facilities, particularly suitable for warehouses with a limited number of SKUs and large quantities of standardized pallets.
Advantages: Forklifts drive directly into the racking lanes to load and retrieve pallets using the LIFO (Last In, First Out) method. The system reduces aisle space, utilizes up to 85% of available warehouse space, and features robust bracing designed for very heavy loads.
Two flexible configurations are available: Single-Entry Drive-In and Double-Entry Drive-In.
Push Back Racking System
Ideal Applications: Storage of heavy packaging pallets, grouping products by designated storage zones, and semi-automated gravity-assisted warehouse operations.
Technical Advantages: The system operates with inclined roller carts. When a forklift loads a new pallet, it pushes the previously stored pallet toward the back of the lane. This enables faster pallet handling, minimizes the need for forklifts to travel deep into the racking lanes, and significantly reduces the risk of forklift impact and structural damage to the steel racking.
Cantilever Racking System
Ideal Applications: A specialized solution for large paper rolls, long paper tubes, industrial paper cores, plastic profiles, and PE/PP film rolls.
Technical Advantages: The open-front design eliminates front upright columns, providing unobstructed access for storing and handling materials with variable lengths. The cantilever arms are structurally engineered to withstand bending loads and support paper rolls securely, helping prevent deformation and facilitating handling with specialized roll-clamp forklifts.
HLM Galvanized Steel Pallets
A Durable Alternative to Wooden & Plastic Pallets
For heavy-duty industries such as packaging, switching from wooden or plastic pallets to HLM galvanized steel pallets or HLM powder-coated steel pallets can be a strategic investment designed to deliver long-term durability and cost efficiency.
Advantages of HLM Steel Pallets
- Exceptional Load Capacity: Supports static loads of more than 3,000 kg and dynamic loads exceeding 1,500 kg without bending or permanent deformation under specified operating conditions.
- Resistant to Paper Dust & Non-Combustible: HLM steel pallets feature a high-quality hot-dip galvanized finish that provides excellent abrasion and corrosion resistance. Unlike wooden pallets, they do not produce wood splinters that can damage packaging and are non-combustible, making them particularly suitable for improving fire safety in paper and packaging warehouses.
- Service Life of 10+ Years: A long service life can significantly reduce pallet replacement and maintenance costs compared with conventional pallet types. HLM steel pallets are compatible with Selective, Drive-In, and Push Back racking systems.
Structural Engineering for Heavy-Duty Loads – “Engineered by HLM”
At Hoa Long Mechanical, we do not simply sell mass-produced warehouse racking modules. Every packaging warehouse project is treated as a specialized engineering project. HLM’s structural engineering team directly surveys the site and rigorously calculates key technical parameters, including:
- Load per individual pallet → evenly distributed load per beam level (beam capacity) → total load across the entire racking bay/row.
- Racking design based on stringent beam deflection requirements, including FEM 10.2.02 where applicable.
- Analysis of the floor slab’s compressive load-bearing capacity, followed by appropriate design of column base plates, structural bracing, and the number of floor anchors to distribute loads effectively and minimize the risk of floor settlement.
- Accurate integration of the racking layout with the automatic water-based fire protection system design, in accordance with the latest applicable Vietnamese standards, including TCVN 14496:2025. This ensures appropriate safety clearances, sprinkler head clearance, and emergency access and egress routes as required by regulations.
What Sets HLM Industrial Warehouse Racking Systems Apart
Operational Fit
HLM conducts on-site surveys, forklift traffic-flow analysis, and measurements of the customer’s actual pallet dimensions before preparing the warehouse layout drawings.
Warranty & After-Sales Service
We are committed to providing long-term structural warranty coverage, technical support, and lifecycle maintenance throughout the project..
Certification
Load capacity inspection certificates and detailed as-built drawings make it easier for businesses to complete project acceptance and handover.
Optimize Carton & Plastic Packaging Warehouse Capacity Now
Hoa Long Mechanical (HLM)’s experienced team of solution engineers is ready to support your warehouse project. We provide on-site condition surveys, warehouse measurements, and free 2D/3D warehouse layout drawings to help optimize storage capacity and operational efficiency.
HOA LONG MECHANICAL PRODUCTION JOINT STOCK COMPANY
Hotline: 0901 890 689
Email: contact@hoalongcorp.com
Website: www.hoalongcorp.com
Engineered by HLM – Built for Real Warehouses
Schedule a Factory SurveyFAQ
Which Racking System Is Suitable for Packaging Warehouses?
It depends on the number of SKUs, pallet load capacity, and required storage density. Common solutions include Selective, Double Deep, Drive-In, Push Back, and Cantilever Racking for rolls and long materials.
Is Drive-In Racking Suitable for Carton Packaging?
Yes. When products are relatively uniform and stored for long periods, Drive-In Racking can significantly increase storage density and reduce aisle space.
Are Steel Pallets Suitable for the Packaging Industry?
Yes. Steel pallets offer high load capacity, resistance to deformation, long service life, and can reduce replacement costs compared with wooden pallets in heavy-load environments.
Does a Heavy-Duty Pallet Racking System Require Reinforcement?
Yes. For high-load pallets, the entire system should be engineered based on the beams, column frames, bracing, column base plates, and floor/foundation capacity to ensure safe operation.
