{"id":77319,"date":"2025-12-22T06:24:15","date_gmt":"2025-12-22T06:24:15","guid":{"rendered":"https:\/\/www.hashmicro.com\/blog\/?p=77319"},"modified":"2026-02-13T08:46:21","modified_gmt":"2026-02-13T08:46:21","slug":"block-stacking","status":"publish","type":"post","link":"https:\/\/www.hashmicro.com\/blog\/block-stacking\/","title":{"rendered":"Block Stacking Explained: A Practical Guide for Warehouse Managers"},"content":{"rendered":"<p>Many warehouses often remain underutilized due to poor layout decisions, leading to rising storage costs, limited floor space, and slower putaway.<\/p>\n<p>To reverse this, block stacking can help you improve your warehouse\u2019s productivity by increasing storage density, especially for uniform SKUs stored in high volumes. <a href=\"https:\/\/www.ivysci.com\/en\/articles\/399739__A_simulationbased_optimization_approach_to_design_optimal_layouts_for_block_stacking_warehouses\" target=\"_blank\" rel=\"noopener noreferrer\">Academic research on block stacking <\/a> shows that a well-designed layout can reduce operational costs by up to ~10% through space optimization.<\/p>\n<p>This page will tell you everything you need to know about block stacking, from its definition to industry best practices. We will also present its pros and cons and compare block stacking with the racking system for warehousing.<\/p>\n<p><!-- <div id=\"toc_group_article\" style=''>\r\n\t<p style='font-size:25px;font-weight:bold; margin-bottom:0px'>\r\n\t\tTable of Content:\r\n\t<\/p>\r\n\t<ul id=\"list_toc\" class='list_toc'><\/ul>\r\n<\/div> -->\r\n\r\n<!-- <div class=\"dropdown-fixed-top\" id=\"dropdown-fixed-top\">\r\n\t<div class=\"row\">\r\n\t\t<p id=\"pilihDaftarIsi\">Table of Content<\/p>\r\n\t\t<p><i class=\"td-icon-menu-down\"><\/i><\/p>\r\n\t<\/div>\r\n\t\r\n\t<div>\r\n\t\t<ul id=\"list_toc_top\" class='list_toc'><\/ul>\r\n\t<\/div>\r\n<\/div> -->\r\n\r\n<div id=\"placeholder-toc\"><\/div>\r\n<div id=\"toc\">\r\n    <div class=\"header\">\r\n\t<span class=\"toc-title\" id=\"toc-title\">Table of Content<\/span>\t\r\n\t <i class=\"toc-icon\">\r\n        <svg xmlns=\"http:\/\/www.w3.org\/2000\/svg\" width=\"30\" height=\"30\" viewBox=\"0 0 24 24\" fill=\"none\" stroke=\"#000\" stroke-width=\"2\" stroke-linecap=\"round\" stroke-linejoin=\"round\" class=\"header-icon\">\r\n          <path d=\"m6 9 6 6 6-6\" \/>\r\n        <\/svg>\r\n      <\/i>\r\n\t<\/div>\r\n    <div class=\"list\">\r\n      <ul id=\"toc-list\"><\/ul>\r\n    <\/div>\r\n <\/div>\r\n\r\n<style>\r\n\t@media (max-width: 992px) {\r\n\t\t#toc_group_article {\r\n\t\t\tpadding-top: 24px;\r\n\t\t}\r\n\t}\r\n\t\r\n\t#list_toc_float {\r\n\t\tmax-height: calc(100vh - 250px);\r\n\t\toverflow-y: auto;\r\n\t}\r\n\t\r\n\t#list_toc_top {\r\n\t\tdisplay: none;\r\n\t\tbackground: #fff;\r\n\t\tmargin-bottom: 4px;\r\n\t}\r\n\t\r\n\t#list_toc_top li {\r\n\t\tdisplay: block;\r\n\t\tmargin-left: 0;\r\n\t\tlist-style: none;\r\n\t}\r\n\t\r\n\t#list_toc_top a {\r\n\t\tpadding: 5px;\r\n\t\tdisplay: block;\r\n\t}\r\n\t\r\n\t#list_toc_top.show {\r\n\t\tdisplay: block;\r\n\t}\r\n\r\n\t#list_toc_top a {\r\n\t\tcolor: #434343;\r\n\t\tborder-bottom: 1px solid #bbb;\r\n\t}\r\n\t\r\n\t.dropdown-fixed-top {\r\n\t\tposition: fixed;\r\n\t\ttop: 59px;\r\n\t\twidth: 100%;\r\n\t\tz-index: 99;\r\n\t\tborder-bottom: 2px solid #9c171e;\r\n\t\tpadding: 12px;\r\n\t\tbackground: #fff;\r\n\t\twidth: 100%;\r\n\t\tcursor: pointer;\r\n\t\tdisplay: none;\r\n\t\tleft: 0;\r\n\t\tbox-shadow: 0 -2px 7px 6px rgba(0, 0, 0, 0.17);\r\n\t}\r\n\t\r\n\t#dropdown-fixed-top.show {\r\n\t\tanimation: showAnim 0.5s ease;\r\n\t\tdisplay: block;\r\n\t\topacity: 1;\r\n\t}\r\n\t\r\n\t@keyframes showAnim {\r\n\t\tfrom {\r\n\t\t\tdisplay: none;\r\n\t\t\topacity: 0;\r\n\t\t}\r\n\t\tto {\r\n\t\t\tdisplay: block;\r\n\t\t\topacity: 1;\r\n\t\t}\r\n\t}\r\n\t\r\n\t.dropdown-fixed-top #list_toc_top {\r\n\t\tmax-height: calc(50vh - 110px);\r\n\t\toverflow-y: scroll;\r\n\t}\r\n\t\r\n\t.dropdown-fixed-top .row {\r\n\t\tdisplay: flex;\r\n\t\tjustify-content: space-between\r\n\t}\r\n\t\r\n\t.dropdown-fixed-top .row p {\r\n\t\tmargin-bottom: 0;\r\n\t}\r\n\t\r\n\t#pilihDaftarIsi {\r\n\t\tmax-width: 100%;\r\n\t\toverflow: hidden;\r\n\t\twhite-space: nowrap;\r\n\t}\r\n\t\r\n\t@media (min-width: 1018px) {\r\n\t\t.dropdown-fixed-top {\r\n\t\t\tdisplay: none;\r\n\t\t}\r\n\t}\r\n\t\r\n\t#list_toc li {margin-bottom: 0;margin-top: 5px;}\r\n\t#list_toc > li > ul {padding-left: 20px;margin-bottom: 0;}\r\n\t#list_toc{height:max-content;transition:ease-in-out}\r\n\t#list_toc li {margin-bottom: 0;margin-top: 5px;}\r\n\t#list_toc_float li.active > a {color:#b1252d;background: #ffe1e3;}\r\n\t#list_toc_top li.active > a {color:#b1252d;background: #ffe1e3;}\r\n\t#list_toc_float li a {padding:3px 7px}\r\n\t#list_toc_float li a {\r\n\t\tdisplay: block;\r\n\t\tcolor: #000;\r\n\t\tmargin-bottom: 6px;\r\n\t\tpadding-top: 2px;\r\n\t\tpadding-bottom: 2px;\r\n\t\ttransition: all 0.2s ease-in-out;\r\n\t\tfont-size: 15px;\r\n\t\tline-height: 18px;\r\n\t}\r\n\t#list_toc_float li{list-style:none;list-style-position:inside; margin-left:0;}\r\n\t#list_toc_float a:hover{color:#b1252d;}\r\n\t\r\n\t#toc_group_float{\r\n\t\tline-height: 24px;\r\n\t\tmax-height: calc(100vh - 100px);\r\n\t\toverflow: auto;\r\n\t\tz-index: 99;\r\n\t\tdisplay:none!important;\r\n\t\tbackground:#fff;\r\n\t\ttransition:all 0.5s linear\r\n\t}\r\n\t\r\n\t@media (min-width:1019px){\r\n\t\t#toc_group_float {\r\n\t\t\tdisplay:block!important;\r\n\t\t\t}\r\n\t\t\t\t#toc_group_article {\r\n\t\t\tdisplay:none;\r\n\t\t}\r\n\t}\r\n\r\n<\/style>\r\n\r\n<!-- ToC styling  -->\r\n<style>\r\n\t\/* Simple styling for the TOC *\/\r\n\t\r\n\t#toc ul li:last-child {\r\n    padding-bottom: 16px; \/* Adjust the value as needed *\/\r\n}\r\n\r\n.td-fix-index {\r\n\t transform: unset !important;\r\n     -webkit-transform: unset !important; \r\n}\r\n.footer-contact .td-fix-index {\r\n\t transform: translateZ(0) !important;\r\n     -webkit-transform: translateZ(0) !important; \r\n}\r\n\t.tdb_single_content .tdb-block-inner.td-fix-index{\r\n\t\tposition: static;\r\n\t}\r\n\t\r\n\r\n\t\r\n#toc {\r\n  background-color: #FFF;\r\n\tpadding: 17px 24px 0px 24px !important;\r\n  margin-bottom: 20px;\r\n\/*   border: 1px solid #9C171E; *\/\r\n  border-radius: 6px;\r\n\tdisplay: none;\r\n  max-width: 100%;\r\n  transition: .4s ease height;\r\n\tmargin-left: 0;\r\n\toverflow: hidden;\r\n}\r\n\r\n#toc .header{\r\n  display: flex;\r\n  align-items: center;\r\n  justify-content: space-between;\r\n\tbackground-color: transparent;\r\n}\r\n\t\r\n\t#toc.sticky .header{\r\n\t\tpadding: 4px 0;\r\n\t}\r\n\t\r\n.header p{\r\n  font-size: 18px !important;\r\n  font-weight: 600 !important;\r\n  color: #393939;\r\n   margin-bottom: 0;\r\n  \/* margin-top: 20px; *\/\r\n}\r\n\r\n.toc-icon{\r\n  float: right;\r\n\/*   visibility: hidden; *\/\r\n}\r\n\r\n\t.toc-title{\r\n\t\tmargin-right: auto;\r\n\/* \t\tpadding-left: 20px; *\/\r\n\t\tfont-weight: 600;\r\n\t\talign-self: center;\t}\t\r\n\r\n#toc ul {\r\n  list-style-type: none;\r\n  padding-left: 0;\r\n}\r\n\t\r\n#toc.sticky ul{\r\n\toverflow-y: auto;\r\n\tmax-height: 250px;\r\n\tmargin-top: 0px;\r\n\tpadding-top: 20px;\r\n\/* \tborder-top: 1px solid #d3d3d3; *\/\r\n}\r\n\t\r\n#toc ul li {\r\n\/*   margin-bottom: 10px; *\/\r\n  margin-bottom: 10px;\r\n\tmargin-left: 0;\r\n\ttransition: .2s ease;\r\n\tcursor: pointer;\r\n}\r\n\t\r\n\t#toc.sticky ul li {\r\n\t  margin-right: 10px;\r\n\t}\r\n\t\r\n.td-post-content #toc-list li a:hover, .td-post-content #toc-list a.active{\r\n\tbackground-color: #FFF;\r\n\/* \tpadding: 8px 16px 8px 16px; *\/\r\n\tpadding: 4px 16px 4px 16px;\r\n\tborder-radius: 6px;\r\n\tcolor: #9c171e !important;\r\n\tfont-weight: 600 !important;\r\n}\r\n\t\r\n\t.td-post-content #toc-list li:hover a, .td-post-content #toc-list a.active{\r\n\t\tcolor: #9C171E !important;\r\n\t\tfont-weight: 600 !important;\r\n\t}\r\n\t\r\n.td-post-content #toc-list a.active{\r\n\tfont-weight: bold !important;\r\n\tcolor: #9C171E !important;\r\n}\r\n\t\r\n#toc a, .td-post-content #toc-list a {\r\n  text-decoration: none;\r\n  color: #ea1717 !important;\r\n  transition: .2s ease;\r\n\tfont-weight: 400 !important;\r\n\tdisplay: block;\r\n\t\r\n\tpadding: 4px 16px 4px 0;\r\n}\r\n\r\n#toc.sticky {\r\n  position: fixed;\r\n\/*   top: 73px; *\/\r\n\tbottom: 0;\r\n  z-index: 100; \r\n  box-shadow: 0 2px 5px rgba(0,0,0,0.1); \r\n\twidth: 100%; \r\n\tbackground-color: #FFF;\r\n\/* \tbackground-color: #FFF1F1; *\/\r\n\tborder-bottom: 1px solid #ea1717;\r\n\/*   border: 1px solid #393939; *\/\r\n  box-shadow: 0px 0px 14px 0px #00000040;\r\n  cursor: pointer;\r\n\tanimation: fadein .3s ease;\r\n\tpadding: 12px 16px !important;\r\n}\r\n\t\r\n\t.fadein{\r\n\t\tanimation: fadein .3s ease;\r\n\t}\r\n\t\r\n\t.fadeout{\r\n\t\tanimation: fadeout .3s ease;\r\n\t}\r\n\t\r\n\t\r\n\t@keyframes fadein{\r\n\t\t0% {\r\n\t\t\topacity: 0;\r\n\t\t}\r\n\t\t100%{\r\n\t\t\topacity: 1;\r\n\t\t}\r\n\t}\r\n\t\r\n\t@keyframes fadeout{\r\n\t\t0% {\r\n\t\t\topacity: 1;\r\n\t\t}\r\n\t\t100%{\r\n\t\t\topacity: 0;\r\n\t\t}\r\n\t}\r\n\r\n\t\r\n#toc.sticky .header p{\r\n\tmargin-bottom: 10px;\r\n\tmargin-top: 10px;\r\n}\r\n\r\n#toc.sticky .toc-icon{\r\n  visibility: visible;\r\n\/* \ttransition: 0.4s ease; *\/\r\n}\r\n\t\r\n\t.toc-icon{\r\n\t\talign-items: center;\r\n    \tdisplay: flex;\r\n\t}\r\n\t\r\n\tsvg.header-icon{\r\n\/* \t\tbackground-color: #9c171e; *\/\r\n\t\tbackground-color: #FFF;\r\n\t\tborder-radius: 30px;\r\n\t\tpadding: 5px;\r\n\t}\r\n\r\n#toc.sticky .list{\r\n\/*   max-height: 0; *\/\r\n  transition: height 0.4s ease;\r\n}\r\n\t\r\n\t#toc .list{\r\n\/*   max-height: 0; *\/\r\n  transition: height 0.4s ease;\r\n}\r\n\r\n#toc .header.active .toc-icon{\r\n\ttransform: rotate(0deg); \r\n\topacity: 1;\r\n}\r\n\r\n\t#toc .header.active + .list {\r\n\t  max-height: 200px; \/* Adjust this value as needed *\/\r\n\t  opacity: 1;\r\n\t}\r\n\t\r\n\t#placeholder-toc{\r\n\/* \t\tdisplay: none; *\/\r\n\t}\r\n\t\r\n\t@media (min-width: 768px) and (max-width: 991px){\r\n\t\t#toc.sticky{\r\n\/* \t\t\ttop: 104px; *\/\r\n\t\t\tbottom: 0px;\r\n\t\t}\r\n\t\t\r\n\t\t#toc{\r\n\t\t\twidth: unset !important;\r\n\t\t}\r\n\t}\r\n\t\r\n\t@media (max-width: 767px){\r\n\t\t#toc{\r\n\t\t\twidth: 100% !important;\r\n\t\t\tdisplay: inline-block;\r\n\t\t}\r\n\t\t\r\n\t\t#toc.sticky{\r\n\t\t\twidth: 90% !important;\r\n\/* \t\t\ttop: 81px; *\/\r\n\t\t\tbottom: 60px;\r\n\t\t\tmargin-left: auto;\r\n\t\t\tmargin-right: auto;\r\n\t\t\tpadding: 0 16px;\r\n\t\t\tright: 5%;\r\n\t\t}\r\n\t}\r\n\t\r\n\t<\/style>\r\n\r\n<!-- ToC List for mobile -->\r\n<script>\r\n \/\/ Generate TOC based on headings\r\ndocument.addEventListener(\"DOMContentLoaded\", function() {\r\n  \/\/ Get the element that will contain the TOC\r\n  const tocList = document.getElementById('toc-list');\r\n\r\n  \/\/ Get the element with the ID 'article-left'\r\n  const article = document.querySelector('.td-post-content');\r\n\r\n  \/\/ Find all h2 elements within 'myarticle'\r\n  const headers = article.getElementsByTagName('h2');\r\n\r\n  \/\/ Loop through the h2 elements and create a list item for each one\r\n  for (let i = 0; i < headers.length; i++) {\r\n    const header = headers[i];\r\n    const headerText = header.textContent;\r\n\/\/     const headerId = 'header-' + i;\r\n    const headerId = headerText\r\n    .toLowerCase()\r\n    .trim()\r\n    .replace(\/[^\\w\\s-]\/g, '')  \/\/ hapus tanda baca\r\n    .replace(\/\\s+\/g, '-'); \/\/ ganti spasi jadi \"-\"\r\n\r\n    \/\/ Set an ID for the header if it doesn't have one\r\n    header.setAttribute('id', headerId);\r\n\r\n    \/\/ Create a list item for the TOC\r\n    const listItem = document.createElement('li');\r\n\r\n    \/\/ Create a link for the list item\r\n    const link = document.createElement('a');\r\n    link.setAttribute('href', '#' + headerId);\r\n    link.textContent = headerText;\r\n\r\n    \/\/ Append the link to the list item\r\n    listItem.appendChild(link);\r\n\r\n    \/\/ Append the list item to the TOC list\r\n    tocList.appendChild(listItem);\r\n  }\r\n});\r\n\r\n\/\/ Keep height and placement of content using placeholder in place of TOC\r\ndocument.addEventListener(\"DOMContentLoaded\", function() {\r\n  const toc = document.querySelector('#toc');\r\n  const placeholderToc = document.querySelector('#placeholder-toc');\r\n\r\n  function setPlaceholderHeight() {\r\n    placeholderToc.style.height = `${toc.offsetHeight}px`;\r\n  }\r\n\r\n  \/\/ Set the initial height of the placeholder\r\n  setPlaceholderHeight();\r\n\r\n  \/\/ Update the height on window resize\r\n  window.addEventListener('resize', setPlaceholderHeight);\r\n});\r\n  const tocTitle = document.querySelector('#toc-title'); \/\/ Assuming header-faq is the element for TOC title\r\n\r\n\/\/ Sticky TOC and update heading\r\ndocument.addEventListener(\"DOMContentLoaded\", function() {\r\n  const toc = document.querySelector('#toc');\r\n  const footer = document.querySelector('.td-footer-template-wrap');\r\n  const tocParent = toc.parentElement;\r\n  const divTop = tocParent.getBoundingClientRect().top + window.pageYOffset;\r\n  const tocHeight = toc.offsetHeight;\r\n  const triggerPoint = divTop + tocHeight + 700;\r\n  const footerHeight = footer.offsetHeight;\r\n  const triggerFooterPoint = footer.getBoundingClientRect().top + window.pageYOffset - footerHeight - footerHeight - footerHeight;\r\n  const phtoc = document.querySelector('#placeholder-toc');\r\n  const headers = document.querySelectorAll('.td-post-content h2');\r\n  const navLinks = document.querySelectorAll('#toc-list a');\r\n\t\r\n\tconst panel2 = document.querySelector(\"#toc .list\");\r\n\tvar icon = document.querySelector(\".toc-icon\");\r\n\r\n  let activeLink = null; \/\/ Declare activeLink outside the loop\r\n\t\r\n  \/\/ Function to handle scroll and add\/remove .sticky class\r\n  function handleScroll() {\r\n    const windowTop = window.pageYOffset || document.documentElement.scrollTop;\r\n    let currentHeader = '';\r\n\r\n    \/\/ Highlight user progress as the heading comes\r\n    headers.forEach(header => {\r\n\t\tconst headerTop = header.offsetTop;\r\n\t\tconst headerHeight = header.clientHeight;\r\n\t\tif (window.scrollY >= (headerTop - headerHeight + 700)) {\r\n\t\t\tconst currentHeaderId = header.getAttribute('id');\r\n\t\t\tconst currentHeaderText = document.getElementById(currentHeaderId).textContent;\r\n\/\/ \t\t\tconsole.log(\"current header text:\", currentHeaderText);\r\n\t\t\ttocTitle.textContent = currentHeaderText;\r\n\t\t\tcurrentHeader = currentHeaderId;\r\n\t\t\t\r\n\t\t\tif(window.innerWidth < 767){\r\n\t\t\t\ttocTitle.textContent = 'Table of Content';\r\n\t\t\t}\r\n\t\t}\r\n\t});\r\n\r\n    navLinks.forEach(link => {\r\n      link.classList.remove('active');\r\n      if(currentHeader != '') {\r\n\t\t  if (link.getAttribute('href').includes(currentHeader)) {\r\n\t\t\t  link.classList.add('active');\r\n\t\t  }\r\n\t  }\r\n    });\r\n\/\/     if (windowTop < triggerFooterPoint) {\r\n\/\/         toc.style.display = 'block';\r\n\/\/ \t}else{\r\n\/\/         toc.style.display = 'none';\r\n\/\/ \t}\r\n    \/\/ Update TOC title if sticky\r\n    if (windowTop > triggerPoint) {\r\n      if (!toc.classList.contains('sticky')) {\r\n        phtoc.style.display = \"block\";\r\n        toc.classList.add('sticky');\r\n        toc.style.width = `${tocParent.offsetWidth}px`; \/\/ Set width to match the parent element\r\n        toc.setAttribute('style', 'width: ' + tocParent.offsetWidth + 'px !important;');\r\n        toc.style.backgroundColor = \"#FFF\";\r\n\t\tpanel2.style.height = '0px';\r\n\t\t  icon.style.transform = \"rotate(180deg)\";\r\n\t\t  if(window.innerWidth < 767){\r\n\/\/ \t\t\t  const tocs = document.querySelector('#toc.sticky');\r\n\t\t\t  tocTitle.textContent = 'Table of Content'; \/\/ Reset title\r\n       \t\t  toc.style.width = '150px'; \/\/ Set width to match the parent element\r\n\t\t  }\r\n      }\r\n      if (currentHeader) {\r\n\/\/         console.log(\"activeLink:\", activeLink);\r\n        if (activeLink) {\r\n\/\/           tocTitle.textContent = activeLink.textContent; \/\/ Update TOC title\r\n          tocTitle.textContent = activeLink ? activeLink.textContent : \"\"; \/\/ Update title only if activeLink exists\r\n        }\r\n      }\r\n    } else {\r\n      toc.classList.remove('sticky');\r\n      phtoc.style.display = \"none\";\r\n      toc.style.width = 'unset'; \/\/ Reset to original width\r\n      toc.style.backgroundColor = \"#FFF\";\r\n      tocTitle.textContent = 'Table of Content'; \/\/ Reset title\r\n\t\tpanel2.style.height = panel2.scrollHeight + \"px\";\r\n\t\ticon.style.transform = \"rotate(180deg)\";\r\n    }\r\n  }\r\n\r\n    \/\/ Attach the scroll event listener to the window\r\n    window.addEventListener('scroll', handleScroll);\r\n\r\n    \/\/ Initial call to handleScroll to set the correct state on load\r\n    handleScroll();\r\n});\r\n\t\r\n\t\/\/ Open toggle TOC\r\n\t  document.addEventListener(\"DOMContentLoaded\", function() {\r\n\t\tvar tocHeader = document.querySelector(\"#toc .header\");\r\n\t\tvar toc = document.querySelector(\"#toc\");\r\n\t\tvar icon = document.querySelector(\".toc-icon\");\r\n\t\tconst tocTitle = document.querySelector('#toc-title');\r\n\t\tconst tocs = document.querySelector('#toc.sticky');\r\n \t\tconst tocParent = toc.parentElement;\t\t  \r\n\r\n\t\t  tocHeader.addEventListener(\"click\", function() {\r\n\t\t\tvar panel = this.nextElementSibling;\r\n\t\t\tif (panel.style.height !== '0px') { \/\/ Check if height is not 0px\r\n\t\t\t  panel.style.height = '0px'; \/\/ Set height to 0 for full collapse\r\n\t\t\t  icon.style.transform = \"rotate(180deg)\";\r\n\/\/ \t\t\t\ttoc.style.paddingBottom = '6px'; \r\n\t\t\t\tif(window.innerWidth > 768){\r\n\t\t\t\t\tif(!toc.classList.contains('sticky')){\r\n\t\t\t\t\t\ttoc.style.width = \"unset\";\r\n\/\/ \t\t\t\t\t\ttoc.setAttribute('style', 'width: ' + tocParent.offsetWidth + 'px !important;');\r\n\t\t\t\t\t}\r\n\t\t\t\t\tif (toc.classList.contains('sticky')){\r\n\t\t\t\t\t\ttoc.style.width = 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{\r\n                const offset = getNavbarHeight();\r\n                const elementPosition = element.getBoundingClientRect().top;\r\n                const offsetPosition = elementPosition - offset-40;\r\n\r\n                window.scrollBy({\r\n                    top: offsetPosition,\r\n                    behavior: 'smooth'\r\n                });\r\n            }\r\n        }\r\n\r\n        \/\/ Fungsi untuk menangani klik pada tautan judul\r\n        function handleTitleClick(event) {\r\n            event.preventDefault();\r\n            const href = event.target.getAttribute('href').substr(1);\r\n            scrollToElementWithOffset(href);\r\n        }\r\n\r\n        \/\/ Tambahkan event listener untuk semua tautan judul\r\n        const titleLinks = document.querySelectorAll('a[href^=\"#\"]');\r\n        titleLinks.forEach(link => {\r\n            link.addEventListener('click', handleTitleClick);\r\n        });\r\n\t});\r\n    <\/script> -->\r\n <a href=\"https:\/\/www.hashmicro.com\/free-product-tour\/?medium=free-product-tour\" target=\"_blank\"><img decoding=\"async\" loading=\"lazy\" width=\"712\" src=\"https:\/\/www.hashmicro.com\/blog\/wp-content\/uploads\/2025\/11\/Free-Product-Tour-resized.webp\" alt=\"Free Demo\"><\/a><\/p>\n<table style=\"border-collapse: collapse; background-color: #fffacd; box-shadow: 0 4px 8px rgba(0, 0, 0, 0.1); border-radius: 25px 25px 25px 25px;\" width=\"100%\">\n<tbody>\n<tr>\n<td style=\"padding: 15px; border: none;\">\n<h3 style=\"margin-bottom: 10px;\"><span style=\"background-color: #8a0e19; color: #ffffff; padding: 5px;\"><b>Key Takeaways<\/b><\/span><\/h3>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><a href=\"#what\">Block stacking<\/a> is a floor-based storage method in which palletized goods are stacked into stable blocks on the warehouse floor rather than placed on fixed racking systems.<\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\"><a href=\"#when\">Block stacking should be used when<\/a> storing high volumes of uniform SKUs that do not require strict FIFO rotation, especially for non-perishable, non-crushable goods and seasonal or overflow inventory, where low setup cost and high density matter more than selectivity.<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\"><a href=\"#best\">Best practices for applying block stacking<\/a> with SKU-based lane assignment include strict stacking height limits, disciplined LIFO putaway\/picking, and WMS-guided lane control to minimize honeycombing, reduce damage risk, and maintain layout efficiency.<\/span><\/li>\n<\/ul>\n<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p><img decoding=\"async\" loading=\"lazy\" class=\"alignnone wp-image-79286 size-full\" src=\"https:\/\/www.hashmicro.com\/blog\/wp-content\/uploads\/2025\/12\/Hash9273Micro.webp\" alt=\"Block stacking infographic\" width=\"800\" height=\"400\" srcset=\"https:\/\/www.hashmicro.com\/blog\/wp-content\/uploads\/2025\/12\/Hash9273Micro.webp 800w, https:\/\/www.hashmicro.com\/blog\/wp-content\/uploads\/2025\/12\/Hash9273Micro-300x150.webp 300w, https:\/\/www.hashmicro.com\/blog\/wp-content\/uploads\/2025\/12\/Hash9273Micro-768x384.webp 768w, https:\/\/www.hashmicro.com\/blog\/wp-content\/uploads\/2025\/12\/Hash9273Micro-150x75.webp 150w, https:\/\/www.hashmicro.com\/blog\/wp-content\/uploads\/2025\/12\/Hash9273Micro-696x348.webp 696w\" sizes=\"auto, (max-width: 800px) 100vw, 800px\" \/><\/p>\n<p>&nbsp;<\/p>\n<h2><strong><span id=\"what\">What Is Block Stacking?<\/span><\/strong><\/h2>\n<p>Block stacking is a warehouse storage method where pallets, bins, or products are stacked directly on the floor in dense blocks or deep rows, often multiple levels high. It avoids steel racking, making it one of the most cost-effective ways to maximize cubic space for high-volume, uniform SKUs.<\/p>\n<p>This method typically follows a <a href=\"https:\/\/www.hashmicro.com\/blog\/inventory-valuation-methods\/\">Last-In, First-Out (LIFO) inventory flow<\/a> because the most recently placed pallet is the easiest to access first. Its biggest advantages are flexible layout changes and lower setup and maintenance costs than those of fixed racking systems.<\/p>\n<h2><strong><span id=\"how\">How Does the Block Stacking Method Work?<\/span><\/strong><\/h2>\n<p><span style=\"font-weight: 400;\">Block stacking is more than just stacking pallets in every available space. It can only work through proper layout planning and adequate rules.\u00a0<\/span><\/p>\n<ol>\n<li><strong>Layout determination and block design<\/strong><br \/>\nStart by mapping floor zones, deep lanes, and access aisles based on SKU volume and turnover. Use clear floor markings and ensure aisle width supports safe forklift movement without sacrificing density.<\/li>\n<li><strong>The pallet stacking process<\/strong><br \/>\nOperators place pallets from the back of a lane and build upward into aligned, stable stacks. Stack height is set by load strength, pallet condition, product weight, and ceiling clearance to prevent crushing and instability.<\/li>\n<li><strong>Goods retrieval and stock rotation<\/strong><br \/>\nPicking follows LIFO, meaning the front or top pallets must be removed first before accessing deeper stock. The method runs most efficiently when each lane holds a single SKU and is fully emptied before refilling.<\/li>\n<li><strong>LIFO-based inventory management<\/strong><br \/>\nInventory control requires consistent lane discipline, so putaway and picking do not break the LIFO flow. A Warehouse Management Software (WMS) helps track lane contents in real time and reduces errors that cause lost stock and honeycombing.<\/li>\n<\/ol>\n<h2><strong>Pros and Cons of Block Stacking<\/strong><\/h2>\n<p><span style=\"font-weight: 400;\">Block stacking is not inherently good and comes with multiple considerations to weigh.<\/span><\/p>\n<h3><b>Pros of Block Stacking<\/b><\/h3>\n<p><span style=\"font-weight: 400;\">Block stacking remains popular because it delivers high storage density without the heavy upfront investment of fixed racking. When the SKU profile and handling flow match, it can improve space efficiency and lower the cost per pallet position.<\/span><\/p>\n<ol>\n<li><strong>Maximum cost efficiency<\/strong><br \/>\nBlock stacking reduces capex because you do not need steel racking, installation, or ongoing structural maintenance. With forklifts and pallets as the main requirements, it keeps storage costs low and improves the cost per pallet position.<\/li>\n<li><strong>Vertical and horizontal space utilization<\/strong><br \/>\nRemoving racking uprights frees more floor area for storage lanes and increases overall density. Pallets can be stacked vertically up to safe limits, maximizing cubic space for bulk, uniform inventory.<\/li>\n<li><strong>Warehouse layout flexibility<br \/>\n<\/strong>Without fixed structures, you can reconfigure lanes quickly to match changing inventory levels or seasonal demand. This makes it easier to adapt the warehouse layout without downtime from dismantling and reinstalling racking.<\/li>\n<li><strong>Simple and fast implementation<\/strong><br \/>\nImplementation is mainly floor planning and marking, so the warehouse can become operational faster than a racking-based setup. Training is also simpler because stacking and retrieval follow familiar forklift handling routines.<\/li>\n<\/ol>\n<h3><b>Cons of Block Stacking<\/b><\/h3>\n<p>Block stacking can deliver high density and low storage cost, but it also introduces access, safety, and space-loss risks if the operation is not disciplined. The good news is that most of these issues can be reduced with the right SKU selection, layout rules, and <a href=\"https:\/\/www.hashmicro.com\/blog\/storage-management\/\">optimal storage management controls<\/a>.<\/p>\n<ol>\n<li><strong>Limited product accessibility (LIFO principle)<\/strong><br \/>\nBecause block stacking follows LIFO, accessing pallets deeper in a lane often causes double handling and delays. Reduce the impact by dedicating lanes to one SKU, aligning putaway with dispatch priorities, and using a WMS to direct operators to the best lanes.<\/li>\n<li><strong>Risk of product damage due to stacking<\/strong><br \/>\nTall stacks can crush lower cartons and become unstable if the packaging, pallets, or load quality is inconsistent. Set maximum stack height\/weight limits, use strong pallets and uniform unit loads, and enforce forklift handling SOPs to protect goods and people.<\/li>\n<li><strong>Emergence of the honeycombing effect<\/strong><br \/>\nPartially emptied lanes create trapped empty space that lowers density and cancels out the main benefit of block stacking. Prevent this by replenishing in full-lane quantities, consolidating leftovers into designated \u201cmix\u201d lanes, and using WMS rules to trigger consolidation at thresholds.<\/li>\n<li><strong>Limitations on stacking height<\/strong><br \/>\nStacking height is constrained by load capacity, ceiling clearance, and safety requirements, leaving vertical space unused. Optimize by selecting products suitable for higher stacks, standardizing pallet patterns, and using a WMS-supported slotting plan to place heavy\/fragile loads in safer, lower blocks.<\/li>\n<\/ol>\n<h2><strong><span id=\"when\">When Should You Use Block Stacking?<\/span><\/strong><\/h2>\n<p>Block stacking works best when your inventory profile matches its strengths: dense storage, simple handling, and low setup cost. Use it when the savings and space gains outweigh the trade-offs of LIFO access and consolidation work.<\/p>\n<ol>\n<li><strong>For uniform and homogeneous products<\/strong><br \/>\nBlock stacking works best for products with consistent size, weight, and packaging because stacks stay stable and predictable. This reduces the risk of damage and allows safer stacking to higher levels.<\/li>\n<li><strong>When stock volume is high with limited SKUs<\/strong><br \/>\nIt performs best when you store large volumes of the same SKU, so each lane can be dedicated to one product. This simplifies handling, reduces reshuffling, and minimizes LIFO friction.<\/li>\n<li><strong>For non-time-sensitive goods<\/strong><br \/>\nBecause retrieval is typically LIFO, block stacking suits items that do not require strict FIFO rotation. It works well for goods shipped in batches where the pick order does not affect quality or compliance.<\/li>\n<li><strong>As a temporary or seasonal storage solution<\/strong><br \/>\nBlock stacking is ideal for overflow storage during peak seasons because it can be set up quickly with minimal infrastructure. Once demand normalizes, the space can be cleared and repurposed without racking changes.<\/li>\n<\/ol>\n<h2><strong>Block Stacking vs. Racking System<\/strong><\/h2>\n<p><img decoding=\"async\" loading=\"lazy\" class=\"aligncenter wp-image-79279\" src=\"https:\/\/www.hashmicro.com\/blog\/wp-content\/uploads\/2025\/12\/Desain-tanpa-judul-4-300x150.webp\" alt=\"Block stacking with racking system comparison\" width=\"800\" height=\"400\" srcset=\"https:\/\/www.hashmicro.com\/blog\/wp-content\/uploads\/2025\/12\/Desain-tanpa-judul-4-300x150.webp 300w, https:\/\/www.hashmicro.com\/blog\/wp-content\/uploads\/2025\/12\/Desain-tanpa-judul-4-768x384.webp 768w, https:\/\/www.hashmicro.com\/blog\/wp-content\/uploads\/2025\/12\/Desain-tanpa-judul-4-150x75.webp 150w, https:\/\/www.hashmicro.com\/blog\/wp-content\/uploads\/2025\/12\/Desain-tanpa-judul-4-696x348.webp 696w, https:\/\/www.hashmicro.com\/blog\/wp-content\/uploads\/2025\/12\/Desain-tanpa-judul-4.webp 800w\" sizes=\"auto, (max-width: 800px) 100vw, 800px\" \/><\/p>\n<p>One of the most fundamental decisions in warehouse design is choosing between the low-cost flexibility of block stacking and the rigidity of <a href=\"https:\/\/www.hashmicro.com\/blog\/warehouse-racking\/\">the warehouse metal racking system<\/a>. This side-by-side analysis provides a practical framework for determining the optimal storage strategy for your warehouse.<\/p>\n<table style=\"width: 100%; border-collapse: collapse;\">\n<tbody>\n<tr>\n<td style=\"background-color: #990000; color: #ffffff; padding: 5px; text-align: center;\"><b>Criterion<\/b><\/td>\n<td style=\"background-color: #990000; color: #ffffff; padding: 5px; text-align: center;\"><b>Block Stacking<\/b><\/td>\n<td style=\"background-color: #990000; color: #ffffff; padding: 5px; text-align: center;\"><b>Racking System<\/b><\/td>\n<\/tr>\n<\/tbody>\n<tbody>\n<tr>\n<td style=\"border: 1px solid #ddd; padding: 8px;\"><strong>Initial Cost<\/strong><\/td>\n<td style=\"border: 1px solid #ddd; padding: 8px;\">Very low. No investment in steel structures is required.<\/td>\n<td style=\"border: 1px solid #ddd; padding: 8px;\">High. Requires significant capital investment for racks, installation, and permits.<\/td>\n<\/tr>\n<tr>\n<td style=\"border: 1px solid #ddd; padding: 8px;\"><strong>Space Utilization<\/strong><\/td>\n<td style=\"border: 1px solid #ddd; padding: 8px;\">Excellent density for low SKU counts but prone to honeycombing. Vertical height is limited by product stability.<\/td>\n<td style=\"border: 1px solid #ddd; padding: 8px;\">Good density with full vertical space utilization. Less prone to wasted space.<\/td>\n<\/tr>\n<tr>\n<td style=\"border: 1px solid #ddd; padding: 8px;\"><strong>Accessibility &amp; Selectivity<\/strong><\/td>\n<td style=\"border: 1px solid #ddd; padding: 8px;\">Very low. Operates on a Last-In, First-Out (LIFO) basis with no direct access to individual pallets.<\/td>\n<td style=\"border: 1px solid #ddd; padding: 8px;\">Excellent. Provides direct access to every pallet, allowing for First-In, First-Out (FIFO) rotation.<\/td>\n<\/tr>\n<tr>\n<td style=\"border: 1px solid #ddd; padding: 8px;\"><strong>Product Suitability<\/strong><\/td>\n<td style=\"border: 1px solid #ddd; padding: 8px;\">Best for uniform, non-crushable, non-perishable products with high volume and few SKUs.<\/td>\n<td style=\"border: 1px solid #ddd; padding: 8px;\">Suitable for a wide variety of product types, sizes, and weights, including those requiring FIFO.<\/td>\n<\/tr>\n<tr>\n<td style=\"border: 1px solid #ddd; padding: 8px;\"><strong>Flexibility<\/strong><\/td>\n<td style=\"border: 1px solid #ddd; padding: 8px;\">Extremely high. The layout can be reconfigured quickly to adapt to changing inventory needs.<\/td>\n<td style=\"border: 1px solid #ddd; padding: 8px;\">Low. The layout is fixed and requires significant effort to modify.<\/td>\n<\/tr>\n<tr>\n<td style=\"border: 1px solid #ddd; padding: 8px;\"><strong>Risk of Damage<\/strong><\/td>\n<td style=\"border: 1px solid #ddd; padding: 8px;\">Higher risk of product crushing and damage from forklift collisions due to deep lanes.<\/td>\n<td style=\"border: 1px solid #ddd; padding: 8px;\">Lower risk, as each pallet is supported by a steel structure, preventing crushing.<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<h2><strong><span id=\"best\">Best Practices for Implementing Block Stacking in a Modern Warehouse<\/span><\/strong><\/h2>\n<p><span style=\"font-weight: 400;\">Block stacking performs best when clear rules, consistent handling, and strong operational discipline support it. With the proper setup, you can protect inventory, reduce wasted space, and keep workflows efficient even in high-density areas. It is also ideal to implement supporting systems, such as a War<\/span><span style=\"font-weight: 400;\">ehouse Management System (WMS)<\/span><span style=\"font-weight: 400;\">, to streamline processes optimally.<\/span><\/p>\n<ol>\n<li><strong>Conduct in-depth product analysis<\/strong><br \/>\nReview each SKU\u2019s weight, dimensions, and packaging strength to confirm it can be stacked safely. Use the findings to set safe stack heights per SKU and prevent crushing or unstable loads.<\/li>\n<li><strong>Design an efficient aisle layout<\/strong><br \/>\nMark lanes and aisles clearly so operators follow a consistent flow and blocks stay organized. Set lane depth based on turnover to limit honeycombing and reduce double handling.<\/li>\n<li><strong>Implement safe stacking height rules<\/strong><br \/>\nDefine maximum stacking heights by product type, pallet condition, and <a href=\"https:\/\/www.hashmicro.com\/blog\/warehouse-safety\/\">standardized safety standards<\/a>, then enforce them consistently. Post the limits in the storage zone and train operators regularly to prevent collapses and damage.<\/li>\n<li><strong>Integrate with a Warehouse Management System (WMS)<\/strong><br \/>\n<span style=\"font-weight: 400;\">Use a WMS to guide putaway and picking so LIFO lanes stay accurate and easy to manage, while providing real-time visibility into pallet locations, lane occupancy, and SKU movement. A WMS also helps track lane utilization, trigger consolidation, and optimize layout decisions over time. It\u2019s best to conduct thorough research before deciding which is <\/span><span style=\"font-weight: 400;\">the best WMS for your business<\/span><span style=\"font-weight: 400;\">.<\/span><\/li>\n<\/ol>\n<a href=\"https:\/\/www.hashmicro.com\/warehouse-management-system?medium=moneysite-banner\" target=\"_blank\"><img decoding=\"async\" loading=\"lazy\" width=\"712\" src=\"https:\/\/www.hashmicro.com\/blog\/wp-content\/uploads\/2022\/03\/Warehouse-Management-System.png\" alt=\"Warehouse Management\"><\/a>\n<h3><strong>FAQ About Block Stacking<\/strong><\/h3>\n<ul class=\"bottom_faq\">\n<li>\n<details>\n<summary><strong>How do you calculate a safe stacking height for block stacking?<\/strong><\/summary>\n<p>Safe stacking height is determined by analyzing product weight, packaging strength, pallet condition, and stability. Always consult manufacturer guidelines and industry safety standards, and never exceed the load capacity of the bottom pallet.<\/p>\n<\/details>\n<\/li>\n<li>\n<details>\n<summary><strong>What is the best strategy to minimize the honeycombing effect?<\/strong><\/summary>\n<p>To minimize honeycombing, dedicate entire lanes to a single SKU and aim to deplete the lane completely before replenishment. A WMS can also help by tracking lane utilization and suggesting consolidation of partially empty lanes to create full, usable spaces.<\/p>\n<\/details>\n<\/li>\n<li>\n<details>\n<summary><strong>What equipment is needed to implement block stacking effectively?<\/strong><\/summary>\n<p>The essential equipment for block stacking is minimal. You primarily need high-quality pallets suitable for stacking and appropriate material handling equipment, such as a forklift or pallet stacker, capable of safely lifting loads to the required height.<\/p>\n<\/details>\n<\/li>\n<li>\n<details>\n<summary><strong>Is block stacking suitable for cold storage warehouses?<\/strong><\/summary>\n<p>Yes, block stacking is very suitable for cold storage. Since racking can be expensive and obstructs airflow, block stacking maximizes storage density and allows for more efficient temperature control, reducing energy costs.<\/p>\n<\/details>\n<\/li>\n<\/ul>\n","protected":false},"excerpt":{"rendered":"<p>Many warehouses often remain underutilized due to poor layout decisions, leading to rising storage costs, limited floor space, and slower putaway. To reverse this, block stacking can help you improve your warehouse\u2019s productivity by increasing storage density, especially for uniform SKUs stored in high volumes. Academic research on block stacking shows that a well-designed layout [&hellip;]<\/p>\n","protected":false},"author":153,"featured_media":79272,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[634],"tags":[],"class_list":{"0":"post-77319","1":"post","2":"type-post","3":"status-publish","4":"format-standard","5":"has-post-thumbnail","7":"category-warehouse"},"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO Premium plugin v26.6 (Yoast SEO v26.6) - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>Block Stacking Strategies for Warehouse Productivity<\/title>\n<meta name=\"description\" content=\"Boost warehouse productivity with block stacking strategies that improve space utilization, speed up picking, and reduce handling errors.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link 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