FMCG WAREHOUSE SHELVES

Challenges in FMCG warehouse management

In the FMCG (fast-moving consumer goods) sector, warehouse management is always a difficult problem due to the diversity of goods, large volumes and continuous import and export needs. Some notable challenges include:

• Extremely high turnover rate of goods: Goods frequently enter and exit the warehouse, requiring the shelf system to be flexible and easily adjusted to meet rapid changes.
• Accurate inventory management: If the data is incorrect, businesses can easily encounter expired or damaged goods, causing cost losses and affecting reputation.
• Space optimization problem: The warehouse must be able to store a large amount of goods while still ensuring clear aisles, convenient for import and export and inventory.
• Diverse storage methods: From single items, boxes to pallets, all require a suitable shelf system to both save space and ensure the safety of the goods.

What do FMCG warehouses need in a racking system?

FMCG warehouses often store large volumes of goods with diverse types, sizes, and particularly high turnover rates. Therefore, their racking systems must go beyond simply “holding” products, and instead meet the following requirements:

• Flexible load capacity: Racking should be designed for a variety of loads—from light (packaged foods, cosmetics) to medium and heavy (beverages, bulk consumer goods). This flexibility allows companies to store different product groups within the same system without needing to rebuild the entire structure.
• Efficient inventory management & retrieval: With products that have short shelf lives, racks must support inventory control based on FIFO (First In – First Out) and LIFO (Last In – First Out) principles. This reduces expired or stagnant goods while improving warehouse efficiency.
• Space optimization: High storage density is common in FMCG warehouses, especially distribution centers. Racking systems must maximize both vertical and floor space, while allowing easy expansion or reconfiguration as storage needs grow.
• Durability & safety: With frequent loading and unloading, racks must be made of robust materials resistant to impacts, while also meeting strict safety standards. Durable racking not only protects goods but also minimizes workplace accidents, extends lifespan, and reduces long-term costs.

Most commonly used FMCG warehouse racking systems

Selecting the right type of racking not only optimizes storage space but also boosts operational efficiency, cuts costs, and supports faster product movement. Below are the most popular racking systems in FMCG warehouses:

1. Heavy-duty racking

Heavy duty racking is a storage system with a very large load capacity, often used to store heavy, bulky pallets of goods such as large-boxed drinks, large quantities of dry food or raw materials. The thick steel structure, sturdy bolt connections and load capacity of several hundred to several thousand kg/floor help ensure absolute safety for goods. This is an ideal solution for large-scale FMCG warehouses that need to store huge amounts of goods and prioritize durability and high stability over many years of continuous operation.

2. Selective racking

Selective racking are the most popular type of shelves in the FMCG sector due to their flexibility and 100% accessibility to pallets of goods. Designed in single or double rows, the shelves allow for both FIFO (first in - first out) and LIFO (last in - first out) methods, suitable for products with short life cycles such as fresh food, milk, soft drinks or promotional goods that need to be imported and exported continuously. The big advantage is that it is easy to expand, the investment cost is reasonable, but the disadvantage is that the storage density is not too high due to the need to leave many aisles.

3. Double deep racking

Double deep racks are designed with two rows of pallets stacked deep together, increasing storage density by about 30–40% compared to traditional Selective racks. This solution is especially useful for medium and large-scale warehouses that need to optimize space while maintaining relatively flexible access. However, to access the pallets at the back, a specialized forklift with a reach truck is required, which means higher equipment investment costs. This is a balanced choice between large storage capacity and moderate investment.

4. Drive-in racking

Drive-in racks have a “tunnel” structure that allows forklifts to move directly into the rack to retrieve pallets. This design helps to maximize the horizontal warehouse space, very suitable for homogeneous, large-quantity shipments that do not require frequent retrieval such as milk, beverages, and packaged foods. However, the ability to access each individual pallet is limited, not suitable for goods that need to be rotated continuously. Drive-in racks are often used in cold storage or long-term storage in the FMCG industry.

5. Radio shuttle racking

Radio shuttle racking is a modern semi-automatic storage system that uses self-propelled shuttle vehicles to move in rack slots to transport pallets. This solution significantly increases storage density, reduces loading and unloading time, and limits forklift collisions with goods. The system is especially suitable for FMCG warehouses with large output, requiring high turnover rates and modern inventory management processes. Although the initial investment cost is high, in the long run, Radio Shuttle racking helps save operating costs and increase circulation efficiency.

6. VNA (Very Narrow Aisle) racking

VNA racks are optimally designed for warehouses with very narrow aisles (only about 1.6-2m), combined with specialized forklifts for retrieval. This structure helps increase storage density by up to 40-50% compared to traditional shelf systems, while maximizing height space. This is an ideal solution for FMCG warehouses located in industrial parks and distribution centers, where space is very expensive. However, it is necessary to invest in specialized VNA forklifts and guide rail systems to ensure safe operation.

7. Flow racks (Carton/Gravity Racks)

Flow racking operates based on the FIFO principle thanks to the inclined roller system, helping the pallet slide from the input end to the output end by gravity. This solution is especially effective for items with short shelf life such as yogurt, soft drinks, candy, etc. because it ensures continuous circulation and avoids expired inventory. In addition, this system also reduces picking time and limits forklift collisions, increasing overall operating efficiency for FMCG warehouses.

8. Cantilever racking

Cantilever racks are designed specifically for long, bulky goods such as plastic pipes, steel bars, industrial wood boards or large packaging rolls. In FMCG warehouses, this type of rack often plays a supporting role in storing large materials, packaging or accessories that cannot be placed on traditional pallets. The outstanding advantage is the ability to customize the length and height of the cantilever flexibly, easy to expand when demand increases, while still ensuring high safety.

9. Light-duty racking

Light-duty shelves are suitable for storing small packaged goods, accessories, consumables or display products. The compact design, easy to disassemble and move flexibly makes this type of shelf very popular in supermarket warehouses, FMCG stores or temporary storage areas. Although not able to bear heavy loads, the shelves still meet the needs of flexible and quick storage with low investment costs.

10. Medium-duty racking

Medium-duty racking have a load capacity of 250-500kg/floor, and are a popular choice in small and medium-sized warehouses thanks to their durability, reasonable price, and ability to adapt to a variety of goods. This type of shelf is suitable for storing dry foods, cosmetics, household goods, fast-moving consumer goods, etc. in storage environments that require stability and the ability to rotate goods regularly. This is a well-balanced solution between load, cost, and space.

11. V-hole iron racking

V-hole iron racks are the most flexible shelf line with the characteristics of being light, easy to disassemble, can change the size of the floors according to needs and especially have the lowest investment cost. Although they cannot withstand large loads, the shelves are still widely used to store light goods, components, accessories, documents or samples in small warehouses, FMCG retail stores. The big advantage is that it is easy to expand and rearrange the warehouse space at any time without spending much money or time.

Special warehouse racking systems

Beyond the common racking systems, some businesses require special racking solutions tailored to unique production and storage needs. These systems are custom-designed to optimize space, load capacity, and safety.

1. Mezzanine floor racking

Mezzanine racks are a shelf system integrated with an operating floor, allowing the warehouse height to be utilized to expand storage space and working area. With a smart design, the shelves not only help increase the usable area many times but can also be combined as an office, light production area or storage of bulky goods.

• Advantages: Maximizes vertical space, flexible design, easy expansion.
• Applications: Logistics warehouses, e-commerce storage, component warehouses, or businesses with large storage needs but limited floor space.

2. Mold racking

Mold racks are specially designed to store molds, machinery and heavy equipment in manufacturing plants. Each shelf level is often integrated with slide rails or a roller system to easily pull and push the mold without using too much force.

• Advantages: High load capacity (hundreds to thousands of kg per level), safe design, efficient handling.
• Applications: Common in plastic, mechanical, mold pressing, electronics, and other industries with large-sized molds.

FMCG warehouse racking solutions from INPA Vietnam

INPA Vietnam delivers comprehensive and professional racking solutions specifically for FMCG—an industry that demands high storage capacity, fast throughput, and accurate inventory control.

• Consulting & customized design: INPA conducts on-site surveys—considering floor area, ceiling height, product density, and operational processes—to propose the most optimal racking solutions.
• Diverse racking systems: From Heavy-Duty, Selective, Drive-In, Double Deep, Radio Shuttle to Mezzanine systems—each designed to match FMCG warehousing needs.
• Cost optimization & efficiency: INPA’s solutions help maximize space usage, lower operating costs, and speed up product turnover.
• Quality & safety assurance: Racks are made from high-quality steel, electrostatic powder-coated, durable, load-resistant, and compliant with safety standards.
• End-to-end services: From consulting, design, manufacturing, installation to warranty and maintenance, INPA supports customers throughout the entire process for long-term efficiency.

See more: Popular chemical warehouse shelving solutions today

With extensive experience in implementing large-scale FMCG warehouse projects nationwide, INPA Vietnam confidently positions itself as a strategic partner, helping businesses build modern, optimized, and sustainable warehouse systems.