When a warehouse handles a large number of SKUs, maximizing storage density is not always the main priority. 

The ability to access each SKU efficiently is.  

For a manufacturing warehouse in Jakarta, our client required a cost-efficient warehouse storage solution that could accommodate a high SKU variety while maintaining direct pallet accessibility. 

The system also needed to work with the reach trucks already operating in the warehouse. 

Several pallet racking configurations can provide cost-effective storage, depending on the required capacity, SKU profile, and material handling operation. 

However, for this project, the combination of high SKU variety, direct pallet access, and compatibility with existing reach trucks made Selective Pallet Racking (SPR) the most practical choice. 

The system provides direct access to every pallet position while allowing the client to continue utilizing its existing material handling equipment, meeting the warehouse’s storage requirements without introducing unnecessary operational complexity or additional MHE investment. 

Project Overview 

Location	Jakarta, Indonesia
Industry	Manufacturing
Solution	Selective Pallet Racking
Storage Capacity	1,000 Pallet Positions
Pallet Size	1,200 × 1,100 × 1,700 mm
Load Capacity	1,000 kg per pallet

Managing Multiple SKUs Without Compromising Accessibility

In this project, direct pallet access was essential because operators needed to be able to retrieve a specific pallet without first relocating other pallets. 

At the same time, the client already operated reach trucks in the warehouse.  

Introducing a storage configuration that required different material handling equipment would increase investment and potentially add unnecessary complexity to daily operations. 

To accommodate these requirements, we installed a 6-meter-high Selective Pallet Racking system with three storage levels, providing approximately 1,000 pallet positions. 

The rack configuration was engineered to accommodate pallets measuring 1,200 × 1,100 × 1,700 mm with loads of up to 1,000 kg per pallet, while maintaining the direct accessibility required for a high-SKU operation. 

Designed Around the Existing Reach Truck

Choosing the right warehouse racking system should not be separated from the material handling equipment operating within it. 

Rack height, aisle dimensions, pallet configuration, and retrieval requirements must work together with the capabilities of the MHE. 

More importantly, existing material handling equipment represents a significant investment. 

A new racking system should therefore make effective use of it whenever operationally suitable. 

For this project, we designed the Selective Pallet Racking system and layout around the client’s existing reach trucks, allowing the warehouse to achieve the required storage capacity and pallet accessibility without changing its existing MHE.  

Enhanced Rack Protection with a New Frame Protector 

Racking design is not only about storage capacity. 

Areas where material handling equipment operates close to the racking also need appropriate protection against accidental impact. 

For this project, Intramega Global implemented a new frame protector design with two supports. 

The additional support provides a stronger protective structure, while the increased protector height extends the coverage area along the lower section of the rack frame. 

This provides greater protection in areas exposed to reach truck movements and helps reduce the risk of direct impact to critical rack components during daily warehouse operations. 

Pre-Galvanized Frames for Long-Term Protection

Our Selective Pallet Racking system also uses pre-galvanized frames for additional corrosion protection. 

Unlike surface finishes that are applied only after the steel has been fabricated, pre-galvanized steel already has a zinc protective coating before it is formed into the rack components. 

This provides additional protection against corrosion and everyday wear, supporting the durability of the racking structure throughout long-term warehouse operations. 

Combined with appropriate rack protection, the material selection provides a more durable storage infrastructure for the warehouse. 

Looking to Optimize Your Warehouse Storage?

The right racking system starts with understanding how your warehouse actually operates.

SKU characteristics, pallet dimensions, storage capacity, material handling equipment, accessibility, cost efficiency.

We always consider each factor before determining the most suitable warehouse storage system. 

So, whether you’re building a new warehouse or upgrading an existing facility, Intramega Global delivers warehouse storage solutions that are designed based on your operational requirements and future business growth.

Planning your next warehouse project?

Let’s discuss the right solution for your operations.

Contact us at +62 811 9121 231