Pallet Flow Rack Testing for Gaylord Boxes

SOLUTIONS

FOR THE TOUGHEST APPLICATIONS

"*" indicates required fields

This field is for validation purposes and should be left unchanged.
NO JOB INQUIRIES HERE
See employment page
Name*
Consent*
Email Signup

Real-World Pallet Flow Testing Reveals What Works—And Pitfalls to Avoid

Large Gaylord-style boxes filled with raw materials are a common sight in manufacturing and processing environments—but can they flow reliably in a pallet flow rack system? That’s the question our Engineering Lab set out to discover. The results? Positive, with a few key takeaways for anyone considering dynamic storage for these oversized loads.

Project Overview – Testing Real-World ConditionsPallet flow for Gaylord boxes | Mallard Manufacturing

Our engineering team tested two lane widths using the same 3-rail wheeled flow system designed to accommodate multiple pallet sizes carrying Gaylord-style boxes weighing between 1500–1850 lbs.

Lane Details:

  • 3-rail wheeled system with 2.9″ diameter wheels
  • 7/16″ per foot pitch
  • Drop-in speed controllers set 56” apart
  • Lane widths: 41” and 44” (out-to-out)
  • Pallet sizes tested:
    • 42″w x 48″d
    • 45″w x 45″d
    • 45″w x 48″d

Test Insight:Pallet flow for Gaylord boxes | Mallard ManufacturingBoth lanes demonstrated smooth, controlled flow thanks to properly spaced speed controllers and solid pallet support. Minor unloading hang-ups were quickly resolved using the plugging method or by introducing another pallet into the lane.

The Plugging Method – Quick Fix for Hang-Ups

If a pallet stalls during unloading, use this proven method to restart the flow:

  1. Lift the front pallet 1″ above the lane.
  2. Use it to gently bump the rear pallets a few inches.
  3. Slowly back out, allowing the flow to resume.

Critical Components Behind the Results

Pallet flow for Gaylord boxes | Mallard Manufacturing Pallet flow for Gaylord boxes | Mallard Manufacturing
M-150 Pallet Flow Wheel Drop-In Speed Controllers
   

Let’s examine the key components that ensured the safe and effective operation of this pallet flow system.

M-150 Pallet Flow Wheels

At the heart of the system are our M-150 high-performance pallet flow wheels. These rugged, 2.9” diameter wheels are engineered to handle demanding, high-throughput environments with consistent, smooth flow—even under heavy loads like the 1500–1850 lb Gaylord pallets used in this test. Constructed with durable resin and mounted on a steel axle for added strength and durability, M-150 wheels deliver long-term reliability and reduce the risk of hang-ups in dynamic storage lanes.

Drop-In Speed Controllers

To maintain safe, controlled pallet movement, drop-in speed controllers were placed at 56” intervals throughout the lane. These compact, self-energizing devices engage automatically with the moving pallet, applying consistent braking force to regulate flow speed—especially important with variable-weight loads. Their drop-in design allows for quick installation and easy repositioning based on load specs, offering a custom-fit solution without added complexity.

A Note About Gaylord Boxes – What to Watch ForPallet flow for Gaylord boxes | Mallard Manufacturing

While our test was successful, Gaylord-style containers present unique challenges for dynamic storage systems. Here are a few concerns to consider during system planning:

  • Box Integrity: Weak, reused, or overfilled Gaylords may bulge or collapse under pressure, especially on gravity-fed systems.
  • Overhang Issues: If boxes extend beyond the pallet footprint, they can interfere with lane rails or rollers.
  • Weight Distribution: Unevenly filled Gaylords can shift during flow, affecting flow speed and alignment.
  • Pallet Compatibility: Avoid loading narrow pallets into wider lanes to reduce skew and ensure reliable tracking.

These risks underscore the importance of real-world pallet flow testing as a vital component of any successful system design. With proper setup and testing, even bulky or irregular loads like Gaylords can flow safely and efficiently.

Final Takeaway – Custom Solutions for Non-Standard Loads

Every pallet flow system should be purpose-built to ensure reliable performance for your specific load characteristics. Whether you’re storing Gaylord boxes, specialty pallets, or variable load weights, Mallard’s gravity flow experts help configure your system and perform comprehensive testing to ensure performance before installation.

Need help with your next storage challenge?
Contact our team to schedule a pallet flow test or explore our dynamic flow rack solutions to meet your warehousing or manufacturing challenges.