Stop 'shipping air' and crushing profits. Your warehouse stores tires, but traditional floor stacking wastes over 60% of your cubic space and causes irreversible bead deformation on your bottom layer. There's a calculated approach to reclaiming that space and protecting every single tire.
In the tire industry, floor stacking—often using methods like "lacing" or "barrel stacking"—seems like a space-efficient solution. In reality, it's a hidden source of massive inefficiency and product loss. This method creates a dense, unstable mass where the tires at the bottom bear the weight of the entire stack. This leads to critical, non-recoverable damage.
The core problem is simple: the tires themselves are being used as the storage structure. This is a fundamental flaw in logistics design.
The solution is to introduce a modular, engineered skeleton that bears 100% of the load. Our portable stack racks act as individual storage cells. The weight of an upper rack is transferred through its steel posts directly to the frame of the rack below it, and ultimately to the floor. The tires inside, whether it's one layer or twenty, experience zero compression. This single change eliminates product damage and unlocks your warehouse's true vertical potential.
A "one-size-fits-all" approach to tire storage is a recipe for inefficiency. Effective high-density design isn't about the rack itself; it's about how the rack's dimensions are calculated based on the specific geometry of the tires it will hold. This ensures maximum space utilization inside the rack and within the shipping container.
The first and most critical calculation is based on tire diameter. This broadly separates passenger car tires from larger truck and commercial tires.
PCR tires optimized for density.
TBR tires engineered for extreme weight.
Once the tire class is determined, we calculate the unit load. For example, if a PCR rack is designed to hold 16 tires averaging 25 Lbs each, the total product weight is 400 Lbs. Adding the rack's self-weight (e.g., 150 Lbs) gives us a total unit load of 550 Lbs. Our metal post pallet systems are typically rated for 2,200 Lbs capacity, allowing for safe stacking of 4 fully loaded units high (550 Lbs x 4 = 2,200 Lbs). This calculation gives you a predictable, safe, and dense storage model, transforming your floor space into a structured, high-rise storage system.
A high-density tire rack is more than just a storage device; it's a reusable transport packaging (RTP) unit that streamlines your entire supply chain. Because the racks are not bolted to the floor, they create a "portable warehouse."
The biggest challenge for any reusable packaging system is the cost of returning empty units. Our pallet stillages are designed with removable posts. After unloading at the destination, the posts are removed and the bases are nested together. In the space that one fully assembled rack occupies, you can stack 4 to 6 nested bases. This simple design feature dramatically increases the density of return shipments, making a closed-loop, sustainable logistics model not just environmentally friendly, but economically superior to disposable one-way packaging.
While custom sizes are our specialty, a typical design for PCR tires (up to 31" diameter) can hold between 16 and 25 tires, depending on whether they are stored on their treads or interlaced horizontally. The final number is a result of a calculation to maximize density for your specific tire SKUs.
Absolutely. We design specific heavy duty stack racks for TBR and even larger OTR tires. These feature reinforced steel bases, thicker gauge posts, and certified welding to handle dynamic loads of 2,500 Lbs or more per rack, ensuring complete safety even when stacked multiple levels high.
Most of our tire rack systems are engineered to be stacked 4 to 5 units high, depending on the unit load and the stability of the floor surface. This allows most warehouses to utilize their full vertical clear height, typically reaching 18 to 24 feet, increasing storage capacity by 400-500% compared to a single layer on the floor.
Unlike dense, solid "laced" stacks which can block water penetration, the open-frame design of our industrial stacking racks allows overhead sprinkler systems to effectively reach all levels of storage. This is a critical factor for compliance with many local fire codes regarding tire storage.
The return on investment comes from multiple areas: (1) Space Savings: Deferring or avoiding the cost of leasing a larger warehouse. (2) Product Savings: Eliminating scrap from compression damage. (3) Labor Savings: Drastically reduced manual handling time for loading, unloading, and picking. (4) Logistics Savings: Lowered return shipping costs due to the nesting feature. Most customers see a full ROI in 12-24 months.
