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Push Back Rack Jam


Push back rack systems are invaluable assets in modern warehouses, facilitating efficient storage and retrieval of goods. However, like any mechanical system, they are susceptible to occasional jams, which can disrupt operations and incur costs. Ideal Warehouse Innovations Inc. recognizes the importance of minimizing push back rack jams to optimize warehouse productivity and safety.

A push back rack system has a great many benefits, and is overall a very efficient system, but it can present its challenges. For example, when there is a jam, no matter the cause, the result is out-of-service pallet positions.As our case study demonstrates, these jams can often create extremely dangerous situations for operators. The solution for this need to perform tasks within a push back racking structure is The MARC - an engineered anchor system that allows operators to move within the racks safely. No more man-handling spilled product or climbing among the racks without an approved anchor point. Watch this video to see The MARC in action!

In this comprehensive guide, we delve into the causes of push back rack jams, effective solutions, and proactive prevention strategies to mitigate their occurrence.

Understanding Push Back Rack Jams
Push back rack systems utilize inclined rails and carts to allow pallets to be stored and retrieved with ease. However, various factors can lead to jams within these systems, including:

Overloading: Exceeding the system's weight capacity can cause jams by placing excessive strain on the rails and carts.
Misalignment: If pallets are not properly aligned during loading or retrieval, they can become wedged within the system, leading to jams.
Mechanical Issues: Wear and tear, damaged components, or faulty installation can contribute to push back rack jams.
Poor Pallet Quality: Irregularities in pallet dimensions or damaged pallets can hinder smooth operation, increasing the risk of jams.
Operator Error: Inadequate training or negligence by warehouse personnel can inadvertently cause jams during pallet handling.

Solutions to Push Back Rack Jams
When faced with a push back rack jam, swift and effective action is essential to minimize downtime and prevent further complications. Ideal Warehouse Innovations Inc. offers the following solutions:

Clear Communication Channels: Establish clear communication protocols between warehouse personnel to promptly address any jam-related issues.
Regular Maintenance: Implement a proactive maintenance schedule to identify and rectify potential issues before they escalate into jams.
Quality Assurance: Ensure that pallets meet specified quality standards to minimize the risk of irregularities that could lead to jams.
Operator Training: Provide comprehensive training to warehouse staff on proper loading, retrieval, and troubleshooting procedures to minimize operator-induced jams.
Mechanical Upgrades: Consider upgrading or retrofitting push back rack systems with advanced components or features designed to enhance reliability and prevent jams.

Prevention Strategies
Preventing push back rack jams is far more cost-effective and efficient than dealing with them after they occur. Ideal Warehouse Innovations Inc. recommends the following proactive strategies:

Regular Inspections: Conduct routine inspections of push back rack systems to identify any potential issues or signs of wear and tear.
Weight Monitoring: Implement weight monitoring systems to ensure that the weight capacity of push back rack systems is not exceeded.
Load Planning: Develop a comprehensive load planning strategy to optimize pallet placement and minimize the risk of misalignment.
Emergency Procedures: Establish clear emergency procedures for addressing push back rack jams to minimize downtime and ensure employee safety.
Continuous Improvement: Foster a culture of continuous improvement within the warehouse environment, encouraging feedback and implementing solutions to enhance system reliability and efficiency.

Push back rack jams can significantly impact warehouse productivity and pose safety risks if not promptly addressed. By understanding the causes of jams, implementing effective solutions, and adopting proactive prevention strategies, warehouses can minimize downtime, reduce costs, and optimize operational efficiency. Ideal Warehouse Innovations Inc. is committed to providing innovative solutions and expertise to help warehouses mitigate the risk of push back rack jams and maximize their storage capabilities. Contact us today to learn more about our comprehensive range of warehouse safety and optimization solutions.


Whether you need warehouse guardrails and trailer jack stands to protect your people or loading dock bumpers and safety barriers to safeguard your equipment, we have a full spectrum of solutions to create a safer workplace. Call 1-866-828-6737 or email us at [email protected] to discuss your needs.