Lacing tires on the floor isn't just inefficient—it's actively destroying your inventory. Every stack creates irreversible bead deformation and flat-spotting on the bottom layers, turning valuable assets into scrap. Meanwhile, your team risks injury manually digging for SKUs, and you're only using a fraction of your warehouse's vertical space. There is a more structured, safe, and profitable way to manage your tire inventory.
In the tire industry, efficient storage is a constant battle against physics and economics. Tires are bulky, heavy, roll, and can't bear significant weight without damage. Traditional storage methods like floor stacking, while seemingly cheap, introduce significant hidden costs that erode your profit margins daily.
The common practice of "lacing" or "barrel stacking" tires to maximize floor space is a primary cause of inventory loss. This method places the entire weight of the stack on the sidewalls of the bottom tires. This leads to:
Floor stacking enforces a strict Last-In, First-Out (LIFO) retrieval system. If a customer needs a specific SKU buried at the bottom of a 20-foot high stack, your warehouse team is forced into a time-consuming and hazardous process of manually unstacking hundreds of tires to reach the one they need. This leads to low operational efficiency, increased labor costs, and an inventory accuracy rate that, according to industry data, can be as low as 85%. You can't sell what you can't find or access quickly.
The Derack system, also known as a portable stack rack or tire pallet, isn't just shelving—it's a fundamental shift in how you handle and store tires. It changes the dynamic from having your product bear the load to having a dedicated steel structure do the work. This simple change unlocks massive efficiency and profitability gains.
The core innovation is simple: tires are placed within a robust steel frame with four removable posts. When another rack is stacked on top, its legs rest securely on the posts of the rack below. The weight is transferred directly through the steel structure to the floor. The result? The tires inside, even at the very bottom of a 5-high stack, experience zero compression. Bead deformation and flat-spotting are completely eliminated.
One size does not fit all. Our tire storage racks are engineered based on a proven diameter classification algorithm. Racks for passenger car (PCR) tires (typically <800mm diameter) are designed to hold a set number of tires perfectly, preventing rolling and maximizing space. For larger Truck and Bus Radial (TBR) tires (>800mm diameter), the base and posts are fortified to handle the extreme weight. This tailored approach allows you to achieve a storage density increase of over 60% compared to floor stacking, effectively turning your warehouse's cubic air space into profitable storage.
Each tire rack functions as a modular, movable unit. Your forklift operator can access any rack, on any level, at any time. This provides 100% selectivity without the need for fixed aisleways of traditional racking. When each rack holds a standardized quantity (e.g., 16 PCR tires), inventory management becomes as simple as counting racks. This dramatically boosts inventory accuracy to 99.9%, simplifies cycle counts, and provides a clear, real-time view of your stock.
These pallet stillages are also a form of Returnable Transport Packaging (RTP). When tires are shipped to distributors or dealers, the empty racks need to be returned. The demountable post design is a game-changer for reverse logistics. The posts can be removed, and the bases can be nested or stacked together. This collapses the footprint of 4-6 empty racks into the space of just one, cutting return shipping freight costs by up to 80% and making your entire supply chain more sustainable and economical.
The key is the "structural load" principle. The weight of stacked racks is supported entirely by the steel corner posts, not the tires inside. This prevents the compression that causes bead deformation and flat-spotting, preserving the quality and value of every tire in your inventory.
Absolutely. The racks are not a one-size-fits-all solution. They are specifically designed and engineered based on tire diameter and weight. Racks for lighter Passenger Car Radials (PCR) are optimized for quantity, while racks for heavy Truck & Bus Radials (TBR) feature a more robust base and thicker steel posts to safely handle the increased load.
No, and that is one of their biggest advantages. Unlike bolted-down pallet racking, these are portable stack racks. They require no installation and can be easily moved and reconfigured by a forklift. In the off-season, you can nest the empty racks in a corner to free up floor space for other activities, providing unparalleled warehouse flexibility.
Safety is paramount. Our heavy duty stack racks are typically designed to be safely stacked 4 to 5 levels high, depending on the weight of the tires, the stability of the floor, and the lift height of your forklifts. This allows you to fully utilize the vertical cube of your warehouse, often up to 6-8 meters (20-26 feet).
Through their nesting design. The corner posts are removable. Once removed, the empty bases can be inter-stacked (nested) together. Typically, you can fit 4 to 6 collapsed empty racks in the same space that one fully assembled rack occupies. This massive reduction in volume leads to a 75-80% saving on reverse logistics freight costs.
