Electric Mobile Racking Systems: Unlock Hidden Space & Increase Storage Capacity by Up to 100%

What is Mobile Racking?

In the face of soaring industrial rents and warehousing costs, maximizing every inch of available space is the key to business success. Mobile Racking is a revolutionary high-density industrial storage system.

Unlike traditional static pallet racking that requires dedicated operating aisles between every row, a mobile racking system mounts pallet racks onto heavy-duty, electrically powered wheeled bases that glide along tracks embedded in the floor. Powered by a smart control system or your Warehouse Management System (WMS), the racks shift to open a single, designated access aisle precisely when and where a forklift needs it. This innovative operational model can increase your absolute storage capacity by up to 100% (or save up to 50% of your current footprint).

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4 Core Advantages of Mobile Racking

Maximize Space Utilization

In a conventional warehouse, operating aisles can consume up to 40% of your total usable floor space. Mobile racking reclaims this wasted space by eliminating permanent aisles, converting them into active storage. For businesses unable to easily relocate or expand their facilities, this is the ultimate solution to expand capacity on-site and maximize the Return on Investment (ROI) of your existing warehouse footprint.

The Perfect Choice for Cold Storage & Cold Chain Logistics

Cold storage facilities incur massive operating costs, requiring enormous amounts of electricity to maintain precise temperatures across a large space. Because mobile racking compresses your storage footprint, it allows you to cool a significantly smaller volume of space while meeting the same (or greater) storage demands. This leads to faster cooling times, reduced strain on cold-chain systems, and massive savings on electricity and cold storage rent.

Fully Customizable to Your Operational Needs

No matter your industry, the BPS professional engineering team can tailor a solution for you. Our mobile racking bases are engineered for extreme durability, with a maximum load capacity exceeding 660 tons per mobile block. The entire system can be precisely adjusted to accommodate virtually any pallet dimension, cargo height, and load requirement. This versatility makes it ideal for Third-Party Logistics (3PL), Fast-Moving Consumer Goods (FMCG), Pharmaceuticals, and Heavy Manufacturing.

Multi-Tiered Safety Systems to Protect Your Workforce

While we maximize storage density, we never compromise on workplace safety. Our electric mobile racking systems are equipped with advanced, industry-leading safety protocols, including:

• Automatic Obstacle Detection Sensors: Instantly halts movement if any personnel, forklift, or debris is detected in the moving aisle.

• Photoelectric Safety Light Curtains: Multiple infrared beams cover the aisle entrances. If the beams are broken while the racks are in motion, the system triggers an immediate emergency stop, safeguarding staff and equipment.

• Intelligent PLC Controllers: Smartly coordinates acceleration and braking speeds to ensure smooth operation, prioritizing the safety of forklift operators and entirely eliminating the risk of crushing or collision injuries.

Case Study: Large-Scale GMP-Certified Healthcare Distribution Centre

BPS Global successfully designed and constructed the largest automated integrated healthcare logistics distribution center in Hong Kong (approximately 140,000 sq. ft.) for a renowned pharmaceutical outsourcing service provider, fully compliant with GMP safety standards and Department of Health (DOH) guidelines.

To help the client overcome challenges related to space utilization, high operating costs, and strict pharmaceutical storage conditions, we seamlessly integrated the Mobile Racking System into a 6,000 sq. ft. 24/7 temperature-controlled cold room.

By combining mobile racking with vertical carousel storage systems and intelligent Automated Guided Vehicles (AGVs), the facility not only drastically increased its storage capacity but also significantly reduced retrieval times and improved batch-picking accuracy. This perfect synergy of high-density storage and automation minimized manual material handling and human errors, driving down long-term operating costs (OPEX) for the client.

Mobile Racking FAQ

Q1: What is the typical Return on Investment (ROI) timeframe for installing a mobile racking system?

While the initial setup cost of an electric mobile racking system is higher than traditional static racking, it yields massive savings by eliminating the need for facility expansion, reducing cold storage electricity bills, and optimizing labor efficiency. Consequently, most of our clients achieve full ROI within 2 to 3 years.

Q2: Will the speed of the moving racks slow down our daily operations and throughput?

No. The system is equipped with advanced PLC controls and remote operation capabilities. Forklift operators can trigger aisle openings via remote control while they are still approaching. By the time the forklift arrives, the aisle is fully opened, ensuring a seamless and highly efficient workflow.

Q3: Can mobile racking be retrofitted into older, existing warehouses?

In most cases, yes. Because mobile racking requires guide tracks to be embedded into the floor, it requires a structural assessment of your existing concrete slab. The BPS engineering team provides a free on-site inspection to evaluate your floor’s load-bearing capacity and offer professional retrofitting recommendations.

Q4: What happens during a power outage?

BPS has fully accounted for emergency scenarios. In addition to being compatible with Uninterruptible Power Supply (UPS) backups, our mobile racking systems are equipped with an emergency manual release and push mechanism. This ensures you can always safely access your critical inventory, even during a total power failure.

Ready to Upgrade Your Warehouse Space?

Don't let inefficient floor layouts limit your business growth. Let the logistics automation experts at BPS Global tailor the most highly optimized Mobile Racking solution for your operations.

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