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Descripción general: Custom Stack Racks & Stillages
Able Hardware manufactures custom stack racks and stillages for B2B buyers who need stackable, forklift-handled storage and returnable packaging. We build portable stacking racks with removable posts, KD transport racks, and pallet cages—engineered to your load (kg), footprint, stacking height, and handling method. For wider programs, we align these designs with Custom Industrial Storage Solutions.
What Are Stack Racks and Stillages?
Stack racks are open-frame racks designed to stack and move by forklift; many use a base plus removable posts/end frames for compact empty storage. Stillages are stackable steel containers—often mesh-sided—for containment and safer staging. Our most requested category is Mesh Stillage Cages for visibility, ventilation, and controlled access.
When to Use Stack Racks vs. Stillage Cages (Open-Frame vs. Mesh Cage)
Use stack racks when you need open access for long or irregular parts, pallets, or dunnage-supported components—especially when KD storage matters. Use stillage cages when containment is required for loose parts, mixed SKUs, or safer floor staging.
Product Types We Build
Bastidores apilables portátiles (Base + Removable Posts)
A rigid base with removable uprights for stackable storage and return loops. Options include 2-way/4-way entry, stacking feet/cups, and optional decks. We can match interfaces with adjacent welded structures such asMarcos de soldadura de metal personalizados for consistent handling clearances.
Knockdown / Collapsible Stack Racks (KD Storage & Return Efficiency)
Posts may be removable, hinged, or nestable to reduce empty-return cube. We engineer sockets, locators, and corner protection to keep KD features reliable.
Envío / Returnable Transport Stack Racks (Part Protection & Cube Optimization)
Transport racks add part-locating features—pins, separators, contact pads—to control orientation and reduce damage. Cost drivers are usually dunnage complexity, required stack height, and protection interfaces for cosmetic parts.
Sheet & Panel Stack Racks (With Side Walls / Guides)
For sheets and panels, we add guides or partial walls to reduce shifting during forklift movement, while maintaining safe access and stable stacking alignment.
Coil Stack Racks / Coil Pallets (Heavy-Duty Cradle Designs)
Coils require controlled cradles and reinforced bases. We design load paths and fork entry around your handling reality, with non-marring interfaces when needed.
Mesh Stillage Cages / Pallet Cages (Visibility, Ventilación, Seguridad)
Mesh cages provide containment with fast visual inventory. Choose fixed walls for robust storage, or half-drop/full-drop gates for picking access. Wire components—partitions, cestas, guards—can be supplied asProductos de alambre personalizados within the same build.
Foldable Pallet Cages / Collapsible Stillages (Return Logistics)
Foldable walls reduce empty-return volume. We prioritize hinge durability, latch consistency, and fold geometry so cages stay square and stackable.
Post Pallets / Post Stillages / Nestainers (Post-Based Stacking Systems)
A lighter alternative to full cages: defined stacking geometry with faster access, often nestable when empty—popular for heavy components and WIP.
Key Design Options and Configurations
Base Styles (Skid Base, Pallet Base, Decked Base)
Skid bases are simple and robust; pallet bases support familiar entry patterns; decked bases help support smaller items. We tune reinforcements to your rated load and impact profile.
Posts and Frames (Corner Posts, End Frames, Removable Uprights)
Post design controls stack stability. We engineer sockets, locators, and stacking cups/feet to reduce slip and improve repeatable alignment.
Decking and Load Support (Open Deck, Wire Mesh Decking, Solid Deck)
Mesh decks improve airflow/visibility; solid decks suit small parts and flat loads. For point loads, we reinforce deck zones and define acceptable deflection.
Side Walls, End Walls, and Containment (Open, Partial, Full)
Containment is chosen by SKU risk: open for easy access, partial for alignment, full for loose goods. Mesh walls also help operators identify parts quickly.
Access Features for Stillages (Half-Drop Gate, Full Drop Gate, Removable Panels)
Half-drop gates support picking; full-drop gates speed bulk loading. We validate clear openings and durable hinge/latch fit.
Forklift Handling (2-Way / 4-Way Entry, Fork Pockets, Stacking Feet)
We design fork pockets and clearances around forklift class and fork dimensions. 4-way entry is feasible but influences base structure, so we optimize it for your approach conditions.
Nesting, Stacking, and Knock-Down Storage (Cube Reduction Strategies)
KD posts, foldable walls, and nestable patterns reduce empty cube. We recommend cube-reduction features only when they lower total loop cost.
Part Protection and Custom Dunnage (Plastic Inserts, Patas, Separators, Contact Pads)
We add non-marring supports and modular dunnage to protect finishes and control orientation. Replaceable wear parts can extend service life.
Labeling and Identification (ID Plates, Label Holders, Barcode Tags)
We add protected ID zones for labels and scanning workflows—important for high-turn, mixed-SKU operations.
Materials and Surface Finishes
Carbon Steel Fabrication Options (Tubo, Ángulo, Sheet, Wire)
Most programs use carbon steel tube/angle bases with sheet and mesh components, selected for load, Resistencia al impacto, and service life.
Stainless Steel Options (Corrosion-Resistant Applications)
Stainless steel is available for washdown/corrosive environments; we can compare life-cycle value versus plated/galvanized carbon steel.
Recubrimiento en polvo (RAL Colors, Coating Thickness)
Powder coating is common for indoor use. We support RAL matching and coating thickness ranges.
Zinc Plating / galvanizado (Corrosion Protection for Harsh Environments)
Zinc plating or galvanizing suits higher humidity and outdoor exposure. We also account for finish effects at stacking interfaces to keep alignment stable.
Performance Specifications and Engineering Criteria
Load Ratings (Static vs. Dynamic, UDL vs. Point Load)
We define ratings in kg and clarify assumptions (static vs dynamic; UDL vs point load) so specs are safe and comparable.
Stacking Ratings (X-High Stacking, Stability Factors)
Stack height drives post design, base stiffness, and interface geometry. We consider uneven floors and handling impacts and can apply rating labels.
Dimensions and Clearances (Internal Usable Space, Fork Openings)
We specify internal usable space, fork entry geometry, and access openings so your pallets/totes/bins fit without wasted cube.
Deflection and Structural Stiffness Targets
We target practical stiffness and deflection limits at rated load, reinforcing critical zones rather than adding weight everywhere.
Typical Tolerances and Fit-Up Requirements (OEM Repeatability)
Key interfaces—post sockets, stacking feet/cups, fork pockets, hinges—are controlled with fixtures and consistent parameters viaServicios de soldadura robótica automatizada.
Applications and Industries We Support
Warehouse Storage and Overflow Racking
Flexible racks and cages supplement fixed racking and help handle seasonal peaks. Many buyers standardize storage with racks/cages plusEstantería Metálica for consistent labeling and finishes.
Manufacturing WIP and Line-Side Staging
We design for fast access, clear identification, and stable stacking in supermarkets and line-side zones.
3PL and Distribution Center Handling
High-cycle environments need durable edges, reliable forklift entry, and protected labels for scanning accuracy.
Automotor, Aparato, HVAC Parts Handling
Returnable packaging often needs part orientation control and non-marring supports; we design dunnage and contact points accordingly.
Export and Returnable Packaging Loops (Return Freight Efficiency)
KD racks and foldable cages reduce empty cube; we also support export packing methods to reduce damage risk and improve landed cost. For broader projects, seeCarros de manejo de material & Bastidores para almacén & Logística.
Fabricación: Robotic Welding and Fabrication Capability
Robotic MIG Welding for Repeatable Weld Quality
Repeatable geometry matters for stacking interfaces and gate alignment. NuestroServicios de soldadura robótica automatizada support stable quality for OEM programs.
Corte, Doblar, and Fixture-Controlled Assembly
We fabricate bases, publicaciones, paneles, and brackets with controlled forming, then assemble in fixtures to improve interchangeability across batches.
Prototype Development and Fast Sample Lead Time
We provide concept + DFM review + prototipos, then refine cost drivers (longitud de soldadura, part count, dunnage design) before mass production.
Small-Batch to High-Volume Production Support
From pilot runs to ongoing supply, we standardize fixtures, inspection points, and packaging so repeat orders stay consistent.
Quality Assurance and Inspection
Incoming Material Control and Traceability
We verify incoming steel/wire and maintain traceability for critical items when your QA plan requires it.
Dimensional Inspection (Critical Interfaces: Publicaciones, Stack Feet, Fork Pockets)
We inspect fork entry, post sockets, stacking cups/feet, and gate openings—interfaces that most strongly affect safety and usability.
Weld Appearance and Structural Verification
We apply weld acceptance criteria and verify high-stress zones; functional stacking and gate checks are used when appropriate.
Surface Finish Inspection (Coating Adhesion, Espesor, Visual Standards)
We check coating thickness/coverage and confirm fit at stacking interfaces to prevent sticking or uneven seating.
Packaging for Export (KD Packing, Palletization, Container Loading)
Packaging is controlled under ourControl de calidad proceso, including KD packing options, protective separators, and container-loading guidance.
Preguntas más frecuentes
Should I Choose Open Stack Racks or Mesh Stillage Cages?
Choose open racks for long/irregular items and quick access; choose mesh cages for loose parts, mixed SKUs, and safer staging. Share part photos and handling flow for a clear recommendation.
Can You Make Knockdown / Collapsible Designs to Reduce Return Freight?
Yes—KD posts, foldable walls, and nestable patterns are common. We size these features based on your loop economics and handling conditions.
What Load and Stacking Ratings Can You Support?
We design across a wide range; final ratings depend on base stiffness, post design, stacking interfaces, and handling impacts. Provide load (kg), stack height, and forklift details.
Can You Add Fork Pockets for 2-Way or 4-Way Entry?
Sí. 4-way entry is feasible but influences base structure and cost; we optimize around your actual approach needs.
Do You Offer Wire Mesh Decking or Solid Decking?
Both. Mesh improves airflow/visibility; solid decks suit small parts. Point-load areas can be reinforced to meet deflection targets.
Can You Add Gates (Half-Drop / Full Drop) for Easier Access?
Sí. We select gate style based on picking speed and safety, and we validate opening size for your bins/totes.
What Materials and Finishes Are Available (Powder Coat vs. Zinc vs. Galvanizado)?
Powder coating for indoor; zinc plating for higher humidity; galvanizing for outdoor/harsh environments; stainless for washdown/corrosive conditions.
What Files Should I Send for an RFQ (2D, 3D, Load, Stack Height, Quantity)?
2D/3D if available, plus load (kg), stacking height, L×An×Al, forklift entry, photos, corrosion environment, finalizar, and target quantity/forecast.
What Are Typical Prototype and Production Lead Times?
Lead time depends on complexity, KD/fold features, finalizar, and volume. We provide a schedule after requirements review.
Call for Action
Send Your RFQ for Custom Stack Racks & Stillages
Able Hardware supports OEM/ODM projects from China with engineered interfaces, repeatable welding, and export-ready inspection. If your system also includes mobile equipment such as anCarro industrial, we can standardize geometry across your handling flow.
What to Include: Load (kg), L×An×Al, Stack Height, Fork Entry, Finalizar, Qty, Use Case
Include: load (kg) and static/dynamic assumption; stacking height; L×W×H and usable space; forklift entry and fork size; containment/gate needs; finalizar; quantity/forecast; and any dunnage or surface-protection requirements.
Get a Fast Concept + Prototype Plan from Our Engineering Team
Send drawings or photos and we’ll reply with an engineered concept, key cost drivers, and a prototype plan. Pricing is quoted as a range (no fixed list price): unit cost is mainly driven by load rating, stacking interface complexity, KD/foldability, mesh/gate structure, dunnage, finalizar, y volumen de orden.
