FMCG and logistics warehouses operate under different operational pressures compared to most industrial warehouses. They handle high inventory volumes, rapid stock turnover, and strict distribution schedules.
Such conditions require an efficient storage or racking system. However, the rack structure itself is only half of the solution. The other half is determined by the storage media placed within those racks.
Why Do FMCG and Logistics Warehouses Need a Different Approach?
Conventional warehouses can operate effectively with simple racking systems because inventory movement is relatively less intensive. Unfortunately, FMCG and logistics warehouses system do not have that advantage.
There are three key characteristics that make racking requirements in these sectors unique:
- High Volume and Fast Turnover. Hundreds to thousands of SKUs move in and out of the warehouse every day. A racking system that does not facilitate quick access to each item can become a significant operational bottleneck.
- Strict Stock Rotation Requirements. FMCG products have expiration dates that must be managed carefully. A racking system that does not support the FIFO (First In, First Out) method can increase operational complexity rather than reduce it.
- High SKU Variety with Different Dimensions. A single FMCG warehouse may handle hundreds of products in varying sizes. A racking system that cannot be reconfigured easily will struggle to accommodate this level of variation.
Learn about how to organize warehouse inventory efficiently as a first step before selecting the most suitable racking system.
Comparison of Racking Systems for FMCG and Logistics Warehouses
To gain a more comprehensive understanding of how each system works, our article on what is racking system? explains them in detail.
Below is a brief comparison of different racking systems for FMCG and logistics warehouses:
| Racking Type | Accessibility | Storage Density | FIFO/LIFO | Komplexity | Estimated Investment |
| ALVAboard (PP Board Storage System) | Very High | Medium | Flexible | Low | Affordable |
| Selective Pallet Racking | Very High | Medium | FIFO | Low | Affordable |
| Drive-In/Drive-Thru Racking | Low | Very High | LIFO/FIFO | Medium | Moderate |
| Push Back Racking | Medium | High | LIFO | Medium | Moderate |
| Pallet Flow Racking | High | High | FIFO | High | Expensive |
| Cantilever Racking | High (for long items) | Medium | Flexible | Low | Moderate |
| Mezzanine Racking | High | Very High | Flexible | High | Expensive |
Recommendations Based on FMCG and Logistics Warehouse Needs
The following recommendations are based on the most common operational requirements found in FMCG and logistics warehouses.
Warehouses That Need a Flexible and Easily Customizable System → ALVAboard Racking System
This system combines a steel rack structure with ALVAboard’s PP board storage media, including bin boxes, pigeon holes, and shelf dividers, all of which can be customized in size and configuration at any time.
The storage media can be replaced, added, or removed without modifying the existing rack structure. This makes it ideal for FMCG and logistics warehouses that require SKU-based storage systems.
Warehouses with Many Product Types and Fast Turnover → Selective Pallet Racking
Each pallet can be accessed directly without moving other pallets. This system is ideal for warehouses that store a wide variety of products and require quick access to all items on a daily basis.
Warehouses Storing Large Quantities of a Single Product → Drive-In Racking
Forklifts enter the rack structure directly to store and retrieve products. While this system offers extremely high storage capacity, accessibility is more limited. It is most efficient for homogeneous products stored in large volumes.
Warehouses with Limited Space but Requiring Higher Capacity → Push Back Racking
This system provides greater storage density than selective racking while offering better accessibility than drive-in racking. It is an excellent choice when warehouse space is limited but stock turnover must remain efficient.
Warehouses Distributing Products with Expiration Dates → Pallet Flow Racking
Products automatically move from the back to the front of the rack using gravity, ensuring that the first products stored are always the first to be retrieved. This system is highly recommended for food, beverage, and pharmaceutical products.
Warehouses Looking to Increase Capacity Without Relocation or Renovation → Mezzanine Racking
This system creates an additional floor level within the existing warehouse. Previously unused vertical space can be transformed into a new storage area.
The Often Overlooked Factor: Storage Media Within the Racking System
Many warehouses already have a well-designed racking system, yet picking processes remain slow and storage space still feels insufficient. One of the main reasons is the storage media used within the racks.
Without proper storage containers, small items can easily become mixed together, operators may struggle to locate products, and available storage space may not be utilized efficiently.
The good news is that ALVAboard provides a solution to this issue. ALVAboard products are specifically designed to complement any racking system already installed in your warehouse.
ALVAboard manufactures three PP board storage solutions specifically designed to enhance modern warehouse racking systems:
Bin Box
A storage container with an open-front design that allows operators to pick items directly from the rack without removing the box.
Available in six color options for visual category coding, equipped with a front label slot, and foldable when not in use.
Dimensions can be fully customized to match rack compartment sizes. It is ideal for warehouses with a large number of SKUs that require quick identification.
Learn more in our article about bin boxes for warehouses and logistics operations.
Pigeon Hole
A storage system that can be expanded, reduced, or rearranged according to operational needs without altering the existing rack structure.
It is highly effective for storing small components, spare parts, or products with a very high SKU variety within a single area.
Shelf Divider
A shelf partition installed directly inside rack compartments to divide storage space into more organized zones.
Its length can be customized, it can be easily removed for cleaning, and it is available in various colors to support category-based color-coding systems.
All three products are made from PP board material that is water-resistant, termite-resistant, lightweight, durable, and reusable. Through its wide range of storage solutions and storage system solutions ALVAboard can be combined with any racking system to create an optimized warehouse storage solution.
Consult your warehouse racking box and storage media requirements with the ALVAboard team via WhatsApp at +62 877 9310 2838 today!
