Posts by Mallard Mfg
Pallet Flow Rack Best Practices for Collapsible Plastic Crates
Design Considerations for Manufacturing Parts Storage with Pallet Flow Rack In parts manufacturing, you often have a known set of SKUs, high on-hand inventory, and a steady pace of replenishment. That’s where pallet flow rack earns its keep: it uses gravity to keep product moving, reduces handling touches, and helps you store deeper without relying…
Read MoreHow to Optimize Ergonomic Case Picking with Controlled Flow and Better Access
Give Your Team a Lift—And Your Case Pick Productivity, Too High-volume case picking is a demanding operation. Between inconsistent pallet styles, heavy loads, and the strain of repetitive motion, it’s easy for efficiency to slip—and for operators to feel the impact. This recent test from the Mallard Engineering Test Lab offers a focused, manageable solution:…
Read MoreBest Practices for Carton Flow Rack in Pick Modules and Packout Zones
How to Prevent Box Shifting and Improve Flow Performance for Stacked Inventory Designing a carton flow system for a pick module or packout zone comes with its own set of challenges — and when that inventory is stacked, things get even trickier. Stacked boxes don’t just need to flow; they need to do so without…
Read MoreNew: Spanish-Language Resources for Mallard Gravity Flow Rack Systems
Ahora en Español: Pallet Flow & Carton Flow Quick Reference Guides Mallard now offers Spanish gravity flow rack resources to help teams install, maintain, and use our systems with more clarity and confidence. We’ve added Spanish versions of key Pallet Flow documents, starting with our Pallet Flow Maintenance brochure and Pallet Flow Installation guide, as…
Read MoreHow to Install Mallard’s Dyna-Pick Warehouse Bin Storage
Maximize Eaches and Small-Parts Storage with This Fast, Clip-In Setup Looking for a fast, flexible way to expand your capacity for piece picking and small parts storage? Mallard’s Dyna-Pick warehouse bin storage system transforms underutilized rack space into high-density, highly organized storage zones—perfect for efficient order picking, kitting, or light assembly. Even better, it installs…
Read MoreBest Practices for Using Pallet Flow Rack with Super Sacks & Winged Pallets
More Than a Wing and a Prayer… Ensure Safe, Consistent Flow for Cargo Pallets in Gravity Flow Rack Handling super sacks in a warehouse environment can be tricky, especially when paired with non-standard “winged” cargo-style pallets. These loads are not only heavy—over 2,000 lbs each—but also rely on a very specific design that demands careful…
Read MoreTop Gravity Flow Rack Wins from 2025 That You Can Use Right Now
Looking Back, Flowing Forward: Highlights from 2025 & What’s Ahead Another year has flown by—and if 2025 taught us anything, it’s to keep expecting the unexpected. From shifting labor demands to evolving facility needs, staying nimble, planning wisely, and investing smartly proved once again to be the keys to staying ahead. At Mallard Manufacturing, we’re…
Read More12 Days of Flow Wins with the Mallard Gravity Flow Team!
Unwrapping 12 Practical Ways To Flow Smarter All Year Long You’ve weathered the rush and managed as best you could. Before the Q1 kickoff hits, now’s the perfect time to catch your breath—and maybe even pick up a few smart ideas for the year ahead. To help you close out the year on a high…
Read MorePush-Back Flow Rack Loading and Unloading: Best Practices for Smooth Operation
Unloading Push-Back Flow Rack Proper loading and unloading techniques aren’t just about keeping things moving—they’re essential for protecting your system and ensuring a safe, efficient work environment. Mishandled pallets can lead to system damage, flow disruptions, or costly delays. While it’s essential that pallets are in good condition for any flow rack system, consistent and…
Read MorePallet Flow Rack Testing for Gaylord Boxes
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…
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