Many warehouse managers eventually run into the question of Interlake “old style” versus “new style” pallet rack systems, especially when expanding existing storage or replacing damaged components. Interlake has been one of the most widely used warehouse pallet racking systems in North America for decades, but the company made several design changes over the years that created differences in how uprights and beams connect. Those changes can make compatibility confusing when working with older rack installations.

A bit about the original design… The original “OLD STYLE” pin design of standard Teardrop style Beams has remained unchanged for decades. The pins were roundish (if not completely round) in shape and were positioned into the larger opening of the inverted teardrop holes on the Uprights. They were then simply pushed down and locked into the smaller portion of the teardrop hole. This simple design, quick installation and safe operation is what has made Teardrop style Racking so widely popular.

INTERLAKE NEW STYLE RACKING

In the late 1990’s, Interlake Mecalux Pallet Rack Systems introduced a new design they termed “NEW STYLE INTERLAKE”. This new design is not considered Teardrop Racking, instead an Interlake proprietary design. What Interlake did was reinvent the locking pins on the Beams to look less rounded and more like an upside down hook. While these hooks might appear to lack the strength of the traditional rounded design, they carry equal strength. These NEW STYLE components were no longer compatible with existing older Teardrop components. As a result, new (“New Style”) Interlake Beams and Uprights would need to be purchased when adding onto existing or replacing.

Now for the confusing part… NEW STYLE Beams were interchangeable with OLD STYLE Teardrop Uprights but OLD STYLE Beams were not interchangeable with NEW STYLE Uprights.

SHAVED PIN BEAM

Fortunately, what Interlake competitors came up with was what is called a “Shaved Pin Beam”. These Beams are compatible with either new or old style Uprights, eliminating all confusion between the two styles. What they did was simply “shave” the rounded connector pin to allow for universal placement into the NEW STYLE Uprights.

This “Interake new style” of Pallet Rack is no longer being manufactured but a substantial amount of it exists today, primarily on the used market.

If you are not sure what type of Pallet Rack Beam you have, we have created a handy PALLET RACK IDENTIFICATION GUIDE. It is designed to help you identify what brand and style of Racking you have. Most historical styles are listed.

Contact the Pallet Rack professionals at Midwest Material Handling, LLC with any questions or for both new and used Racking options!

Every so often, a project comes along that’s not only rewarding, but also a lot of fun to be part of. A few years back, a unique project with BrewDog Brewing in Canal Winchester, Ohio definitely fits that description! What started as a single, small Pallet Rack order turned into a large, multi-stage pallet racking installation that supported both their production needs and their customer-facing space.

Before the project even began, we initially coordinated with BrewDog’s team headquartered in Scotland, which added another unique layer of communication and planning. Their team was fantastic to work with and helped set the foundation for the early stages of the installation before everything shifted to the Canal Winchester location.

If you’ve ever been inside BrewDog’s facility, you know it’s a busy place… constantly moving product, constantly growing, and always looking for ways to operate more efficiently. That meant they needed storage solutions that could keep up with their pace, but also give them the flexibility to expand as their needs changed. Instead of ordering everything at once, BrewDog purchased their pallet rack in stages, adding on as new areas were built out and as the brewery continued to scale.

A Project That Grew Alongside the Brewery

The first phase focused on back-of-house storage. We installed heavy-duty pallet racking to help them organize incoming ingredients, packaged beer and brewery equipment. With the amount of product they move in and out each week, improving the flow of materials was a high priority. The new racking immediately made a difference by giving them more vertical storage and reducing clutter on the warehouse floor.

As the project continued, BrewDog expanded their front-of-house retail space. They wanted racking solutions that looked clean and professional but were sturdy enough to hold cases, merch, and seasonal items. We matched the design to their existing layout so everything looked intentional, not just functional.

Each new stage added another layer to the overall footprint, and before long, the job evolved into a very large installation. By the final phase, the system we had built together supported a wide range of operational needs, from production to retail.

Teamwork, Flexibility and a Great Partner

One of the most enjoyable parts of this project was the collaboration. BrewDog knew what they needed, and we helped them figure out the safest and most efficient way to achieve it. Timing was important, and since they were purchasing racking as needed, we made sure each phase was scheduled and installed in a way that didn’t slow down their daily operations.

It’s always rewarding to step back at the end of a project like this and see how much the space has transformed, especially knowing the system will support BrewDog’s growth for years to come.

A Look Ahead…

Whether it’s a small add-on or a large multi-stage installation like this one, we take pride in helping businesses build storage systems that actually work for the way they operate. BrewDog was a great partner throughout the process, and we’re proud to have played a small role in their continued success in Canal Winchester.

If your business is expanding or you’re considering updating your storage layout, allow the team of experts at Midwest Material Handling, LLC to help you explore the options!