Stop treating your manufacturing floor like a museum. Fixed racking creates rigid aisles that kill your ability to adapt to model changeovers (facelifts) or fluctuating buffer stock levels. In the automotive supply chain, if your storage can't move as fast as your assembly line, you are bleeding efficiency. It’s time to switch from static storage to dynamic, modular WIP buffers.
Talk With An ExpertIn Tier 1 and OEM manufacturing, Work-In-Progress (WIP) is the necessary evil. You need line-side buffers for sequencing, but components like exhaust systems, rear axles, and body panels defy standard palletization. They are long, heavy, or possess Class-A surfaces that cannot bear weight.
Traditional selective racking fails here for two reasons: limited dimensions and permanence. You cannot tear down bolted uprights every time the engineering department changes a bumper design. Industrial stacking racks solve this by converting the floor space into a vertical, movable warehouse that adapts to the part, not the other way around.
Long, tubular components like exhaust assemblies or drive shafts are notoriously difficult to store. When stacked on the floor, they roll. When placed in standard bins, they tangle (the "spaghetti effect"), leading to extended picking times and potential bending.
Double-stacked long-span racks securing tubular components without direct contact pressure.
Our heavy-duty stack racks utilize a post-and-base architecture. The weight of the upper loads is transferred exclusively through the steel posts, not the components. For long parts, we remove the side beams, allowing overhang if necessary, or install custom dunnage to cradle the pipes. This ensures that a calibrated exhaust pipe remains straight from the welding station to the final assembly line.
The tire mounting line is often the most space-hungry section of an assembly plant. Storing mounted wheel assemblies (WIP) before they are sequenced to the vehicle requires immense density. "Lacing" tires on the floor damages the sidewalls and bead integrity over time.
By implementing a portable rack system, you can stack wheel assemblies 4 to 5 levels high. The open-frame design provides full visibility for inventory counting (visual management) and allows fire suppression systems to penetrate the stack—a critical compliance requirement for rubber storage that solid shelving often fails to meet.
For Tier 1 suppliers shipping to OEMs (e.g., shipping seats or instrument panels), the cost isn't just in the delivery; it's in the return trip. Rigid racks mean you are paying to ship "air" back to your facility.
Derack's industrial stacking racks are designed for the closed-loop supply chain. When empty, the posts are removed, and the bases nest into one another.
| Feature | Traditional Rigid Rack | Derack Nestable System |
|---|---|---|
| Return Ratio | 1:1 (Costly) | 4:1 (Efficient) |
| Space when Empty | 100% of footprint | 20-25% of footprint |
| Repairability | Difficult (Welded structure) | Easy (Replace bent posts only) |
This "Nesting" capability means a standard 53-foot trailer that brought parts to the OEM can return hundreds of empty racks in a single trip, slashing your freight spend by up to 75% compared to fixed cages.
For stamped metal parts like doors, hoods, and fenders, the slightest scratch results in scrap. Unlike generic pallets, our racks can be outfitted with specialized textile pockets or rubberized dunnage. The rack becomes the packaging.
Parts are loaded once at the stamping press and remain in the same rack through painting, buffering, and transport until they reach the assembly line. This eliminates double-handling and the associated risk of damage.
1. Can these racks handle the weight of engine blocks or transmission assemblies?
Yes. Our heavy-duty models are engineered using Q235 steel and can be rated for loads exceeding 2,200 lbs (1000 kg) per rack. For concentrated loads like engines, we reinforce the base with additional C-channel supports to prevent deflection.
2. How do these compare to plastic bulk bins for automotive parts?
Plastic bins are excellent for small loose parts but fail with large, irregular items (exhausts, bumpers). Steel stacking racks offer higher weight capacities, better durability against forklift impact, and can be customized with dimensions that plastic molding cannot match without expensive tooling.
3. We have a "Model Year" change coming up. Are these racks adjustable?
The footprint is fixed, but the vertical clearance is adjustable by simply changing the post height. If your new car model has a taller roofline or deeper component, you only need to order longer posts, not entirely new racks.
4. Will the racks rust if stored outside in the yard?
We recommend Hot-Dip Galvanization (zinc coating >60 microns) for any automotive racks that will be exposed to the elements or transported on open flatbeds. This provides self-healing corrosion protection that lasts 15-20 years, far superior to standard powder coating.
5. Can these racks work with AGVs (Automated Guided Vehicles)?
Yes. We can design the base with specific fork pockets or guide runners to ensure compatibility with your specific AGV or AMR system, ensuring seamless integration into automated lines.
