Push-Back Racking for Specialty Frozen Food Warehouse

The Project

Push-back racking installation for a specialty frozen food warehouse that had been floor-stacking pallets inside its freezer. Hammerhead designed and installed 4-deep and 6-deep push-back lanes two levels high, doubling storage from 120 pallets to 240 in the same room and giving the crew a single pick face for every lane.

The Challenge

Everything in the freezer sat on the floor, stacked several pallets deep. Reaching anything at the back of a pile meant moving the pallets in front of it first, which burned time on every put-away and every pick and made it hard to keep an accurate picture of what was in inventory. The room was already full at 120 high-value pallets, and adding freezer square footage was not on the table.

The Outcome

Hammerhead installed 4-deep and 6-deep push-back lanes stacked two levels high, taking the freezer from 120 pallet positions to 240 without expanding the room. Each lane holds one SKU behind a single pick face, so the crew loads and pulls from the aisle instead of digging through a stack. Storage and retrieval rates went up, inventory got easier to organize lane by lane, and the second elevation put more high-value product over floor space the customer was already paying to keep frozen.