Rack Capacity Calculator
Honeycombing costs a fifth of nominal capacity.
Usable unit capacity
121,651
506 usable pallet positions
Honeycombing is the empty space left when a partly-emptied pallet position cannot take another SKU. It typically costs 10% to 20% of nominal capacity, and it is the main reason a warehouse fills up before the pallet count says it should.
How the Rack Capacity Calculator works
Honeycombing is the empty space left when a partly-emptied position cannot take another SKU. It typically costs 10% to 20% of nominal capacity and it is the main reason a warehouse fills up before the pallet count says it should.
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Frequently asked questions
What is honeycombing?
Wasted space in a rack position that is partly empty but cannot be shared with another SKU. It is inherent to single-SKU-per-location storage and increases as pallets are picked down.
How much capacity does it cost?
Commonly 10% to 20% of nominal positions, higher with deep-lane or drive-in racking where whole lanes are dedicated to one SKU.
How do I reduce it?
Mixed-SKU pallets in reserve, dynamic slotting that consolidates part-pallets, and smaller pick faces replenished more often. Each adds handling and saves space.
What utilisation should I plan for?
Around 85% of usable positions is the practical ceiling. Above that, putaway and picking slow down because there is nowhere to move things temporarily.