Double Deep Pallet Racking Manufacturer in Delhi NCR
- Density: Stores 2 pallet positions deep from a single aisle
- Capacity: 1,000 kg to 2,500 kg per pallet position
- Space gain: Increases warehouse floor capacity by 40% to 50%
- Equipment: Operated with specialized pantograph or reach trucks
Star Labs
APT
Adani Defence and Aerospace
Globe Moving
Unilever Nepal Limited
Nepal Electricity Authority
Coca Cola
Mangalam Group
MAW Building Trust Through Service
CG Motors
Save the Children
USAID
Double Deep Pallet Racking Engineering & System Operation
What is Double Deep Pallet Racking? Double deep pallet racking stores pallets two positions deep in back-to-back rows instead of single-deep rows. By eliminating every second access aisle across the warehouse floor, the system increases storage capacity by 30% to 40% on the same footprint. Operates on a Last-In, First-Out (LIFO) cycle per storage lane using deep-reach pantograph forklifts or telescopic fork trucks.
Where is it Used? Cold storage warehouses, food processing buffers, paper and packaging reserves, beverage distribution, and operations with 4 to 10 pallets per SKU.
Key Benefits & Advantages:
• Increases warehouse cubic pallet storage capacity by up to 40% over standard selective racking.
• Halves operating aisle requirements, reducing building footprint and lighting/heating costs.
• Upper beam levels fitted with mechanical pallet backstops to prevent rear over-travel.
• Heavier gauge upright profiles (2.0 mm to 2.5 mm) engineered to resist eccentric reach-fork loads.
How Vaishno Storage Solution Manufactures This System: Manufactured in Mundka using heavy structural steel coils with reinforced diagonal bracing. Uprights are CNC-punched with teardrop or slotted keyholes on 50 mm centers. Heavy step-beams carry welded lower guide channels and rear pallet backstops. Treated through our 7-tank anti-corrosion chemical wash before electrostatic powder coating.
How We Install on Site: Erected with heavy-duty structural floor guide rails along aisle bases to assist pantograph reach truck drivers during deep-bay positioning. Columns are double-anchored to the floor slab with certified high-shear anchor bolts and interconnected with rigid tubular portal overhead ties.
Recommended Applications & Operating Environments
Cold storage buffers, high-volume consumer goods, building material staging, pharmaceutical wholesale holding bays.
Request Factory Quote
Direct Mundka plant rates & 2D CAD layout.
| Parameter | Specification Details |
|---|---|
| Storage Configuration | 2 pallets deep per aisle side (4 pallets back-to-back) |
| Upright Frame Depth | 2,100 mm to 2,400 mm (combined double bay depth) |
| Pallet Weight Rating | 1,000 kg to 2,500 kg per pallet position |
| Material Grade | IS 2062 Grade Prime High-Tensile Structural Steel |
| Operating Forklift Type | Reach Truck with Pantograph or Deep-Reach Telescopic Forks |
| Beam Pitch Adjustment | 50 mm pitch with dual spring safety locks |
| Upper Pallet Guide Rails | Optional guide rails for upper beam blind positioning |
| Surface Treatment | 7-Tank Pre-Treatment + Electrostatic Powder Coating |
Available Sizes & Variants
| Model / Size | Load Capacity | Recommended Application |
|---|---|---|
| Medium Capacity (1000 kg/pallet) | 2,000 kg per 2-pallet beam tier | FMCG packaged foods & consumer goods |
| Heavy Capacity (1500 kg/pallet) | 3,000 kg per 2-pallet beam tier | Chemical drums, auto components & raw materials |
| Extra Heavy (2000 kg/pallet) | 4,000 kg per 2-pallet beam tier | Cold storage frozen cartons & bulk commodities |
Double Deep Pallet Racking B2B Price Benchmark
| Parameter | Vaishno (Factory Direct) | Trader Reseller |
|---|---|---|
| Price | ₹2,200 – ₹5,000 per pallet position | +18% to +30% higher |
| Steel Grade | Prime IS 2062 Grade certified (Tata/JSW) | Re-rolled unverified |
| Paint Finish | 7-Tank + 80µ powder coat | Air-dry spray paint |
| CAD Layout | Free 2D/3D certified layout within 24h | Rough estimates |
| Rigging Crew | Factory-certified riggers with anchors | Unskilled labor |
Direct Fabrication & Testing
All upright columns, horizontal step beams, and steel deck panels are manufactured at our Mundka facility using automated multi-station roll-forming lines and precision CNC slot punching. Sourced exclusively from Tata Steel, JSW, and SAIL with verified Mill Test Certificates (MTC).
Fast Logistics & Turnkey Erection
Our structural installation crews serve warehouses across Delhi NCR, Haryana, UP, Rajasthan, and Punjab with on-site laser leveling, optical plumb inspection, and certified heavy-duty floor chemical anchoring.
How We Manufacture & Install Double Deep Pallet Racking
Manufacturing at Mundka Plant
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1
Prime Steel Profiling High tensile IS 2062 Grade E250 / E350 steel slitted and inspected for yield strength consistency.
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2
CNC Cold Roll-Forming Automated multi-stand cold roll forming lines produce continuous profiles with precise 50 mm pitch perforations.
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3
7-Tank Chemical Pre-Treatment Hot alkaline degreasing, derusting, water rinses, and zinc phosphating create superior powder bonding and rust resistance.
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4
Electrostatic Powder Coating Thermosetting epoxy-polyester powder applied at 70–80 microns and baked at 200°C for industrial scratch resistance.
On-Site Turnkey Installation
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1
Floor Slab & Laser Plumb Check Optical laser levels assess warehouse concrete floor flatness, expansion joints, and plumb lines prior to erection.
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2
Heavy Duty Chemical / Mechanical Anchoring Base plates secured with M12/M16 high-grade anchor bolts embedded into the industrial concrete floor slab.
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3
Safety Locks & Cross-Bracing Spring-loaded safety pins prevent accidental beam dislodgement from forklift contact, supplemented by horizontal and diagonal cross-ties.
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4
Load Testing & Signage Sign-Off Rigorous deflection checks under live weight followed by affixing certified UDL load capacity safety signboards.
How Double Deep Pallet Racking Compares
Factors Determining Double Deep Pallet Racking Cost
Double Deep Pallet Racking Frequently Asked Questions
Direct answers on load carrying capacity, deflection limits, fabrication lead times, and site installation.
Warehouse Guides
Technical articles on warehouse layout planning, safety compliance, and load calculations.
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