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PULL-OUT UNITS

Pallet Pull-Out Units For Ergonomic Order Picking

When operators bend under beams and reach to the back of the pallet, picking gets slow and strenuous. Pallet pull-out units bring the load into the aisle, in new warehouses and in existing pallet racking.

Plan your picking zone Discover the product family
1,000 kg Per pull-out unit, up to
3 sides Access to the load
4 pull-out unit types For pallets and small parts
WHAT ARE PALLET PULL-OUT UNITS

What Are Pallet Pull-Out Units?

A pallet pull-out unit, also called a pallet drawer, is a platform on runners inside the pallet racking. It moves the pallet or load carrier out of the bay, so the operator picks from up to three sides in an upright working position. Dexion pull-out units are mounted on beams, on uprights or on the floor, are operated by hand or electrically and carry up to 1,000 kg. They optimise person-to-goods picking with shorter travel times, better ergonomics and a faster picking process, without changing to automated goods-to-person systems.

YOUR STARTING POINT

Which Situation Describes Your Warehouse

Find your starting point and the pull-out solution that matches it.

Picking from the bottom pallet level

Operators bend under the beam, the back half of the pallet is out of reach and cartons are pulled forward by hand. What helps: pull-out units in the existing rack.

Rack full, assortment growing

Every new pick face costs rack length or floor space. The bottom levels hold one pallet with empty clearance above it. What helps: low-profile units turn clearance into pick levels.

New warehouse or new picking zone

Picking stays manual for now and the layout must remain open for growth. What helps: pull-out levels planned into P90 racking from the start, with universal or upright units.

Heavy components, frequent picks

Pulling 1,000 kg by hand is not an option, and a forklift is tied up for every access. What helps: units that move at the push of a button.

Small parts in deep shelving

Boxes sit at the back of deep shelves, search times grow and items are overlooked. What helps: modules that move the whole shelf to the operator.

PERSON-TO-GOODS, OPTIMISED

How Pull-Out Units Improve Person-to-Goods Picking

In most warehouses the picker still walks to the goods. Pull-out units keep this principle and remove its losses.

Shorter travel times

More pick faces per metre of rack bring the assortment closer together.

Better ergonomics

No bending under beams, no reaching to the back of the pallet.

Faster picking process

Access from three sides, every item in view, less searching.

Less handling

No pallet truck or forklift needed to reach the back of a pallet.

The Load Comes to the Operator

Pull-out units bring pallets, containers and small parts into the aisle. The operator picks in an upright position, from three sides, with every item in view.

COMPARISON

Person-to-Goods or Goods-to-Person Picking

Pull-out units close the gap between static positions and automation.

Static positions

Goods stay inside the rack bay.

  • Person-to-goods
  • Lowest initial cost
  • Goods stay inside the rack
  • Back of the pallet hard to reach
  • Pick faces limited by clearance

Pull-out units

The load comes into the aisle.

  • Person-to-goods, optimised
  • Moderate investment
  • Load comes into the aisle, accessible from three sides
  • More pick faces in the same rack
  • No software, controls or drive maintenance

Automated storage

Goods come to the operator.

  • Goods-to-person
  • Highest investment
  • Software, controls and service contracts
  • Very high throughput, 24/7 operation

Pull-out units can be a first step. The P90 platform allows automation later without replacing the racking.

SELECTION GUIDE

Which Pull-Out Unit Fits Your Requirement

Start with your need. The final selection follows the load and rack check.

UNIVERSAL

  • Retrofit and flexible layouts
  • Beam or floor mounting
  • Extraction: 62 to 100% or two-way
  • Load: 300 to 1,000 kg

UPRIGHT

  • More pick levels per bay
  • Mounted on uprights
  • Extraction: 62 to 100%
  • Load: 500 to 1,000 kg

ELECTRIC

  • Heavy loads, many cycles
  • Beam, upright or floor
  • Extraction: 840 or 1,100 mm
  • 230 V or 18 V battery

COMPACT MODULES

  • Small parts, production supply
  • 880 mm wide, fixed or mobile
  • Extraction: 70 or 100% shelves
  • Load: 150 to 300 kg per shelf
PRODUCT FAMILIES

Pallet Pull-Out Units and Compact Modules by Dexion

Four families for pallets, containers and small parts, plus special designs for heavy and long goods.

Pallet racking with universal pull-out units on every level, one pallet collar extended
Universal Pull-Out Units
For existing racking and flexible layouts. Beam or floor mounting, 300 to 1,000 kg per unit.
Explore the Solution
Pallet racking with upright pull-out units on several levels below pallet storage
Upright Pull-Out Units
More pick levels in the same rack height. Mounted on the uprights, 500 to 1,000 kg per unit.
Explore the Solution
Pallet racking with electric pull-out units on three levels
Electric Pull-Out Units
Powered extension for heavy loads and frequent picks. Up to 1,000 kg, on 230 V or an 18 V battery.
Explore the Solution
Operator picking from a pull-out shelf of a compact module with small-parts containers
Compact Modules
Pull-out modules for small parts, 880 mm wide to fit between pallet racks. Fixed or mobile.
Explore the Solution
Heavy-duty pull-out units with sheet-metal blanks in a production plant
Customised Pull-Out Units
Special designs for very heavy goods, drums and barrels, long goods and units with dividers.
Contact us for Custom Solutions
FROM PLANNING TO SERVICE

One Partner From Planning to Service

Dexion covers the whole project: planning, installation, commissioning and service from the manufacturer.

Planning
Analysis of picking process and goods, layout and model selection, load check of beams, uprights and floor.
Installation
Installation of racking and pull-out units, also in phases during running operation.
Commissioning
Function and safety check, load signs and documentation, briefing of operators.
Service
Rack inspection, maintenance packages and spare parts from the manufacturer.
Inspection, maintenance and spare parts come directly from the manufacturer.
CUSTOMER STORY

Project Spotlight

How Danfoss gained picking locations and better working positions

Operator picking from an extended pull-out unit in the pallet racking at Danfoss
Retrofit project

Danfoss: pull-out units with 100 % extension in pallet racking

Danfoss in Aabenraa, Denmark, needed to make better use of limited space while improving working conditions for staff. Pull-out units with 100% extension were installed on two levels in the pallet racking, bringing goods to a comfortable working height. Operators can now pick with less stretching and bending, while the full room height is put to use.

+33% Storage capacity
6 instead of 4 Picking locations
100% Extension
MANUFACTURING RETROFIT PALLET RACKING DENMARK
Read full case study
"We have been surprised by the amount of space saved thanks to this solution."
Jannik Hollænder Jensen
Danfoss
SAFETY

Safe Picking With Pull-Out Units in Pallet Racking

Load, mounting and operation are planned and checked for every project.

Beam and upright load

An extended unit shifts the load to the front, so capacity is checked for the extended position.

One unit per beam section

Only one pull-out unit per beam section is extended at a time.

Closed when not in use

Units not in use are pushed back and stay closed.

Pallet stops and anchoring

Stops position the load; fixed units are anchored to the floor.

Powered safety

Electric units have a stop function and collision sensing.

Inspection and service

Rack inspection, maintenance and spare parts.

FAQ

Frequently Asked Questions About Pallet Pull-Out Units

Answers on planning, load, safety and cost

What is a pallet pull-out unit?

A pallet pull-out unit is a platform on runners inside pallet racking that moves a pallet or load carrier into the aisle. The operator picks from three sides in an upright position instead of reaching into the bay. Dexion pull-out units are mounted on beams, on uprights or on the floor.

How much weight can a pallet pull-out unit carry?

Manual Dexion pull-out units carry 300 to 1,000 kg per unit, depending on model and mounting. Trays and shelves carry 200 to 300 kg. Electric units carry up to 1,000 kg evenly distributed.

Which pallets and load carriers fit on a pull-out unit?

Pull-out units are built for pallets, pallet collars and other load carriers. The load surface is matched to the pallet and the rack during planning. Special sizes are available as customised units.

How do pull-out units make order picking more ergonomic?

The load comes out of the rack into the aisle, so operators no longer bend under the beam or reach to the back of the pallet. Picking happens from three sides at a comfortable height. Electric models also remove the effort of pulling and pushing heavy loads.

How do pull-out units create more picking locations?

Picking takes place in the extended position, so less hand clearance is needed above each load. The levels in a bay can sit closer together, and the same rack height holds more pick levels. Upright units, with their low construction height, gain the most levels.

Can pull-out units be retrofitted into existing pallet racking?

Yes, in most cases. Beam-mounted units are fitted to the existing beams, and floor units stand on their own. Because an extended unit shifts the load to the front, Dexion checks beam capacity, upright load and anchoring before installation.

What is the difference between 70 % and 100 % extension?

With 62 to 70 % extension the front part of the load comes into the aisle, which is enough for regular access to the front of a pallet. With 100 % extension the whole load surface comes out and every item is in reach. Two-way models open to both sides of the rack.

When is an electric pull-out unit the right choice?

When loads are heavy, picks are frequent or operators should not pull loads by hand. Dexion electric units move up to 1,000 kg with 840 or 1,100 mm extension in about 7 to 12 seconds, on 230 V mains power or an exchangeable 18 V battery.

Can several pull-out units be extended at the same time?

No. Only one pull-out unit per beam section may be extended at a time, because an extended unit shifts its load to the front beam. Units not in use are pushed back.

What do pallet pull-out units cost?

There is no fixed price, because the cost depends on model, load, extension, number of units and the condition of the racking. For a first estimate, Dexion needs the rack type, the load per unit, the pallet size and the number of pick positions.

Pull-out units or automated storage, which fits better?

Pull-out units fit when picking stays manual, volumes are moderate and the layout must stay flexible. They need no software or controls. Automated systems such as vertical lift modules or shuttles suit very high throughput and 24/7 operation. P90 racking with pull-out units can be automated later.

Does Dexion handle planning, installation and service?

Yes. Dexion plans the picking zone, checks the racking, installs and commissions the units. Rack inspection, maintenance and spare parts come from the manufacturer.

Plan Your Picking Zone

Tell us about your current picking setup, including rack type, load, pallet or container dimensions, and picks per day. Our engineers will recommend the right layout and pull-out units for your needs.

Talk to an engineer
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