Block Storage

Description of block storage

In block storage, stackable storage goods (usually designed as floor block storage) are arranged directly next to and on top of each other. This is a special type of storage where stackable boxes, cartons or pallets are stacked in blocks without shelves or other storage racks.

A block storage system can consist of different stored goods. The stored goods are usually moved with forklift trucks or cranes. Block storage systems have some advantages over other forms of storage, such as a higher storage capacity per square metre, better utilisation of the available space and easier handling of the stored goods.

However, there are also some challenges that need to be considered when setting up and operating a block storage facility. Advantages include the low cost of setting up a block storage facility and disadvantages include the lower flexibility compared to other forms of storage. In the following, you will learn more about the areas of application, advantages, special features and challenges of a block storage facility.

Areas of application of a block storage system

The storage unit must be a stackable storage unit, here a distinction can be made between non-pressure-sensitive or stable storage goods and pressure-sensitive or unstable storage goods. In the case of non-pressure-sensitive goods, such as sheetrock, the pallets can be stacked on top of each other. Pressure-sensitive goods, on the other hand, require e.g. mesh box pallets.

Block storage is thus suitable for goods that can be stacked, such as tyres, beverages, etc. The blocks of a warehouse are divided into storage rows. As a rule, only identical storage goods are stored per row in order to have direct access to each storage good. Since only the outer storage units are in direct access, blocks are usually formed with only one item.

This type of storage is mainly used in areas where large quantities of the same stored goods are stored with a small assortment at the same time, with low access frequency due to high withdrawal quantities at the same time.

Advantages of a block storage system

• Relatively low investment costs, high costs for storage equipment (e.g. pallet racks) are low or eliminated in this case
• Fast adaptation to changing needs, high flexibility
• Low space requirement with good clarity, i.e. high degree of space utilisation
• Not susceptible to faults, high availability

Disadvantages of a block storage system

• With different stored goods in a block, direct access to a specific stored good is only possible with difficulty or infrequently
• Pressure-sensitive or unstable stored goods must be repacked into mesh box pallets (storage boxes) prior to block storage, which can result in additional costs
• In the case of one-sided accessibility, the First In, First Out (FIFO) principle is only possible with difficulty; in this case, only the Last In, First Out (LIFO) principle can be used
• Automation is not possible
• Unfavourable inventory management and control with a larger number of articles