Boost Efficiency & Savings - Gravity Flow Rack for Food Distribution
Time, temperature, and turnover are the constant pressures in grocery distribution. Whether you're managing frozen meats, dairy, fresh produce, or packaged snacks, every SKU has storage requirements that can impact shelf life and safety.
That’s where Mallard's gravity flow rack systems help you stay ahead.
Engineered to keep your team productive and your product moving, our gravity-driven, high-density systems manage inventory with precision, speed, and minimal energy consumption. From ambient zones to coolers and freezers, Mallard systems perform—day in and day out.
Why Gravity Flow Systems Are Essential for Grocery Warehousing
- FIFO rotation: Preserve freshness and prevent spoilage
- LIFO option: Space-saving push-back flow rack
- Power-free: Ideal for temperature-controlled environments
- Maximized storage density: Save space without sacrificing access
- Streamlined pick/replenish: Fewer touches, fewer errors, faster throughput
Double the Storage, Half the Footprint!
Gravity Flow Rack Systems for Every Grocery Operation
From inbound to outbound, ambient to freezer, Mallard’s gravity systems adapt to every stage of your grocery distribution process.
- Palletized inventory - high-density storage
- Case picked inventory - high-turn grocery SKUs
- Layer picking & pallet building - streamlined, high efficiency
- Dock staging -organized, fast-moving shipping lanes
If you think you know gravity flow... we’re here to show you more. Our team can help you rethink what’s possible with a system built for freshness, flexibility, and flow.
Pallet Flow Rack: FIFO for Perishables
Magnum Wheel Pallet Flow for Frozen Food Warehousing
Freshness has a deadline. For grocery warehousing, nothing supports product rotation better than Mallard’s pallet flow rack systems.
Designed for temperature-sensitive SKUs—frozen foods, dairy, and produce—pallet flow enables First-In/First-Out (FIFO) rotation to preserve shelf life and reduce spoilage. When space and speed matter, Mallard delivers.
High-Density Without High Complexity
2 to 20+ pallets deep-lane storage
High capacity without ASRS-level complexity
Ideal for coolers, freezers, and fast-turn zones
Meet the Magnum Wheel Advantage
At the heart of Mallard’s pallet flow durability is our Magnum wheel—a game-changer for demanding environments:
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High-impact polymer stands up to extreme cold, wash-downs, and heavy loads
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Wider diameter for better load stability
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Sealed ball bearings & metal axles for long life and low maintenance
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Lifetime Abuse Warranty — unmatched in the industry
Cold Storage. High Throughput. Mallard Strong.
With Magnum wheels and the power of gravity, Mallard pallet flow systems offer deep storage, fast turns, and cold-hardened durability—exactly what your food distribution center demands.
Push-Back Rack: Fast Access. Minimal Footprint. Maximum ROI.
Push-Back Flow Rack
Mallard’s push-back racking delivers efficient, high-density pallet storage in space-constrained environments—especially valuable in grocery and cold storage facilities where every inch of cube costs.
Palletized inventory is loaded and unloaded from a single aisle, with SKUs stored in individual lanes 2 to 12 pallets deep. As each new pallet is added, it “pushes back” the previous load; when one is picked, the rear pallets automatically flow forward.
This Last-In/First-Out (LIFO) configuration minimizes aisle space and maximizes storage capacity—without sacrificing selectivity or system control.
- Batch Processing & Order Picking – Perfect for managing staging zones or preparing route-specific and customer-specific loads
- Seasonal & Promotional Inventory – Short-term SKUs can be rotated quickly without taking up FIFO rack space
- Cold Storage – Smaller footprint reduces refrigeration demands while optimizing reserve or high-turn replenishment inventory
Mallard offers two push-back rack options to fit varying inventory profiles and operational goals.
Our push-back systems deliver gravity-driven efficiency and flexibility for real-world grocery warehousing challenges.
High-Volume Mixed-SKU Pallet Building -- Zero Bottlenecks
Mixed-SKU Pallet Building - The Ergo Build Solution
Fulfilling customized pallet orders for grocery and retail food distribution requires speed, accuracy, and a system that keeps operations moving —without delays, manual searching, or congestion. That’s precisely what Mallard’s patent-pending Ergo-Build delivers.
Built around our innovative EB Separator and Forklift Separator, the Ergo-Build solution creates a gravity-driven flow environment that enables continuous layer picking and mixed-SKU pallet building—all without complex automation or process interruptions. Customers have achieved 11-to-1 labor savings by implementing the Ergo Build solution vs. manual picking.
Dual-Lane Efficiency: Inbound & Outbound Inventory, Always Moving
Ergo-Build systems are designed with inbound and outbound pallet flow lanes that flank the pick aisle, on one or both sides, depending on SKU mix and volume demands. The system accommodates forklifts with layer-pick attachments or robotic arm setups.
- Inbound Lanes (with Forklift Separators) continually feed fresh inventory forward to the pick aisle, ensuring SKUs are always available when needed—no waiting, no searching.,
- Outbound Lanes (with EB Separators) serve as active build zones. Mixed-SKU pallets are assembled directly in the flow lane, held securely in place by the EB Separator during the build. Once complete, a quick release allows the pallet to flow to an outside aisle for pickup, clearing the lane for the next order.
This continuous motion keeps inventory and outbound pallets flowing, eliminating aisle congestion, idle time, or workflow gaps.
Whether you're supplying national food retailers or specialty grocers, Ergo-Build brings structure, speed, and scalability to your outbound fulfillment zone.
Carton Flow Rack: Efficient Picking Starts Here
Cart-Trak Roller Carton Flow Rack
High-volume grocery SKUs like dry goods, packaged snacks, and shelf-stable items require fast, accurate picking with minimal strain on the operator. That’s where carton flow racking delivers measurable results.
Designed for split- and full-case picking, carton flow organizes SKUs into dedicated lanes, automatically replenished via gravity. As items are picked, new product flows forward, keeping pick faces full—without reaching, bending, or wasted motion..
Ergonomic shelf design reduces operator strain, while gravity-fed lanes ensure a constantly stocked pick face. The result? Faster picks, fewer errors, and seamless replenishment. Plus, built-in FIFO flow helps protect date-sensitive SKUs and keep operations compliant, even in cooler or washdown environments.
See how Mallard carton flow racks deliver on every front:
Carton Flow Rack Features:
- FIFO carton, tote, and eaches storage shelves
- High-capacity, consolidated pick zone
- Self-replenishing pick face with wheeled or roller tracks
- Ergonomically convenient for faster, more accurate picks
- Slim-FitTM full-length dividers keep SKU lanes orderly in fast-turn and deep lane environments
- Compatible with washdown requirements
Carton flow racking can be installed as a standalone solution, integrated into multi-level rack systems, or used in pick modules and tunnels to maximize productivity and warehouse space.
Gravity Conveyor: Reliable Flow Without the Power Bill
No motors. No maintenance headaches.
Mallard’s gravity conveyor systems offer a durable, cost-effective, and efficient way to move pallets, totes, containers, and cartons throughout your grocery or food distribution facility.
Flexible Designs for Every Application
Mallard conveyors can be installed with:
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A slight pitch for automatic flow
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A flat orientation for push-assisted movement
Perfect for:
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Pick-and-pack areas
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Short-distance transfers
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Loading dock intake and staging
Skate wheel conveyors for lightweight standalone and temporary applications.
Conveyor Accessories
To enhance system functionality, Mallard provides a full line of conveyor accessories, including:
- Ball transfer tables and mats – for smooth, multi-directional product movement
- Hydraulic lift gates – for convenient access through conveyor lines
- Guide rails – for safe, controlled product tracking
Each system is constructed for long-term use with adjustable height options and rounded-edge designs prioritizing worker safety in high-traffic zones. These small yet critical details make a big difference in building a safer, more efficient operation.
From Concept to Peak Performance
Navigating your flow racking options can feel complex, but you have a dedicated team by your side. Mallard’s gravity flow rack experts take you from concept to go-live.
- Design & Test – We run your actual inventory through our Engineering Test Lab, perfecting pallet flow, carton flow, push-back rack, and gravity conveyors for peak performance.
- Install & Support – Our team provides installation guidance and maintenance support for long-lasting value.
Let’s streamline your operation—Contact us today.
