10-drawer Bplarack for aluminum door panel sheet storage

Core challenge

Diamond Doors Inc also works with aluminum sheet stock in large custom door production. The storage problem here is different: operators need fast, repeated access to sheet material without turning the upper levels into dead space or forcing unnecessary handling with every pick.

Project requirements

The requirement focused on aluminum sheet storage with a horizontal pull-out rack. Material handling needed to work with manual drawer access together with crane and suction-lifter sheet picking.

The final structure used 10 drawer levels. The total rack height was controlled at 2000 mm, and the top drawer operating height was 1790.5 mm so that operators could still work the upper levels in normal daily use.

10-drawer Bplarack front elevation with 2000 mm total height and 1790.5 mm top drawer operating height

Structural specifications

This Bplarack used a full 10-drawer pull-out structure. The spacing between drawers was 85 mm. The drawer size was 3077 × 1550 mm, customized to the required aluminum sheet format.

When both side doors were opened, the total width became 3220 mm. When closed, the doors reduced the occupied width and saved aisle space around the rack.

Bplarack with side doors opened to 3220 mm width for aluminum sheet access

The frame used multiple rear reinforcement details to reduce sway, and the four corners were fixed by triangular reinforcement plates. The structure was designed to stay compact while still giving 10 organized levels inside a 2000 mm high frame.

10-level Bplarack frame designed for compact aluminum panel storage and pull-out access

Why this layout fits aluminum door panel production

Aluminum sheets scratch easily and lose value quickly when storage gets sloppy. A full pull-out drawer structure helps because each level can be targeted directly instead of forcing operators to disturb multiple sheets just to reach one.

For a custom door manufacturer, that means faster picking, cleaner separation by size or job, and less avoidable surface damage before fabrication begins.

Completed 10-drawer Bplarack rack for aluminum sheet organization in custom door manufacturing

Operations insight

This layout is useful because it keeps the rack low enough for practical operation while still delivering 10 separate storage positions. That balance matters more than chasing maximum level count on paper.

Risk and maintenance

  • The 85 mm drawer spacing should be checked against the real sheet thickness and lifting clearance in use.
  • Door opening width should be matched against the available aisle space around the rack.
  • Because aluminum surface quality matters, operators should avoid unnecessary dragging or contact during loading and unloading.

Send your aluminum panel sizes, handling method, and target level count to get a custom Bplarack layout within 48 hours.