Stop sacrificing your warehouse yield to compression damage.
In the flour and feed milling industry, relying on floor stacking or wooden pallets alone is a calculated risk that often fails. Dampness creeps up from the concrete, bottom-layer bags burst under pressure, and wooden splinters contaminate your HACCP-controlled zones. It is time to upgrade to a storage system that respects the integrity of your ingredients.
For Plant Managers at milling facilities (like those producing Swan Flour or bulk animal feeds), the conflict between storage density and product integrity is a daily battle. You produce soft wheat flour or hygroscopic whey powder that comes in 25kg or 50kg bags.
The traditional method of "pyramid stacking" pallets on the floor creates three major problems specific to the food industry:
The metal post pallet (often called a stillage or portable stack rack) fundamentally changes the physics of your storage. Instead of the flour bags supporting the weight of the stack, the steel columns take 100% of the vertical load.
Figure 1: Safe vertical stacking of palletized goods without crushing the bottom layer.
This allows you to take a standard wooden or plastic pallet loaded with 50 bags of flour, place it inside the steel frame, and stack them 4 to 5 units high. The result? Zero pressure on the bottom bags. You effectively convert your warehouse air space into usable storage without installing permanent, inflexible racking systems that restrict your forklift movement.
In feed production, particularly for sensitive products like "Hog Starter" or "Aqua Feed," managing humidity is critical to preventing mycotoxins. Static floor stacking traps heat and moisture between pallets.
Our portable stack racks are designed with this in mind:
1. Galvanized Finish: Unlike painted racks that chip and rust (creating Foreign Object Debris risks), Hot-Dip Galvanized racks are corrosion-resistant and can withstand steam cleaning or washdowns without rusting. 2. Ventilated Bases: The open frame or mesh base design allows cool air to circulate under the pallet, preventing the "sweating" that occurs when warm feed bags meet cold concrete floors.
Figure 2: The open mesh base facilitates air circulation, crucial for preventing mold in organic feeds.
For millers distributing from main production hubs (e.g., Cebu or Manila) to satellite warehouses or large bakeries, the return trip cost is often a dealbreaker. You cannot afford to ship "air" back to the factory.
The nesting capability of the heavy duty stack racks solves this. Once the flour is unloaded at the bakery, the posts are removed, and the bases nest into each other. You can fit approximately 200 empty nested racks into a truck that could only carry 40 full ones. This makes a circular logistics model economically viable.
Figure 3: Empty racks are dismantled and tightly nested to minimize return shipping volume.
| Feature | Standard Wooden Pallet | Steel Post Pallet (Derack) |
|---|---|---|
| Load Capacity | 1,500 - 2,200 lbs (Dynamic) | 3,300 - 4,400 lbs (Per Rack) |
| Stackability | Relies on product strength (Crushing risk) | Self-supporting steel posts (4-5 High) |
| Hygiene | High Risk (Absorbs liquid, splintering) | Food Safe (Washable, non-porous) |
| Lifespan | 1-2 Years (High repair rate) | 10-15+ Years (Galvanized steel) |
Q1: Can these racks hold heavy "Super Sacks" or FIBC bulk bags of grain?
Yes. Our heavy duty stack racks are specifically engineered to handle dynamic loads of up to 2000kg (4400 lbs). The cupped feet design ensures stability even when holding shifting loads like grain bulk bags.
Q2: We use standard 1200x1000mm plastic pallets. Will they fit?
Absolutely. We customize the base dimensions to perfectly accommodate your existing pallet fleet. The rack acts as an "armor" around your plastic pallet, protecting it from forklift impact damage.
Q3: How do these racks help with FIFO (First-In-First-Out) management?
Unlike block stacking where the "oldest" product is trapped at the bottom rear, pallet stillages can be moved individually. A forklift can easily relocate the top racks to access older batches at the bottom without manual restacking.
Q4: Are the racks resistant to fumigation chemicals?
Yes. The hot-dip galvanized coating provides a metallurgical bond that is highly resistant to the chemical agents used in pest control and fumigation processes within food warehouses.
Q5: Do you ship to the Philippines or Southeast Asia?
Yes, we have extensive experience supplying to the ASEAN food and agriculture sector. The nesting design ensures that sea freight costs are minimized, allowing us to ship hundreds of units in a single 40ft container.
