Can Carton Flow Rack Handle Different Box and Tote Sizes? We Put It to the Test
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How Dyna-Flo HD Makes Carton Flow for Manufacturing Seamless
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We recently ran a test for a manufacturing client who needed a storage solution to handle a mix of carton and tote sizes—each with unique shapes, styles, and weights ranging from 5 to 40 pounds. As shown in our test video, Dyna-Flo HD delivered consistent, reliable flow performance across all 15 test items. Whether for cartons or totes, the system proved it could handle each application, making it a smart choice for facilities managing diverse storage needs. Here’s how it worked. |
The Test: One Rack, 15 Cartons & Totes, Zero Issues
For this manufacturing customer, flexibility was non-negotiable. Their warehouse stores a mix of parts and finished goods in an array of containers, so we needed to simulate real-world conditions with variable weights and dimensions.
We used:
- Six 16″ Dyna-Flo HD tracks across a 96″ beam
- Set at a ¾” pitch for optimal pitch-to-depth ratio
- A shelf depth of 8 feet
Each container—10 cartons and 5 totes—was loaded with a weight simulating the customer’s actual product. Despite their wide variety, every item flowed smoothly, thanks to the high-capacity wheel bed and smart configuration using Slim-Fit™ full-length lane dividers.
Key Advantages Observed:
- Full use of shelf space with Slim-Fit™ dividers—each lane configured to the exact carton or tote width
- No sticking or hang-ups, even with heavy or long boxes
- Consistent flow performance even with heavier totes (up to 40 lbs)—no tip-overs, no lane adjustments needed
Are You Familiar with Carton Flow Rack?
Carton flow rack is a dynamic, gravity-fed shelving system engineered for efficient order picking. The system is loaded from one aisle and picked from the other, keeping forklift traffic and pickers safely separated. Inventory flows down inclined wheeled or roller tracks to the front pick aisle, ensuring first-in/first-out (FIFO) rotation.
Because inventory is consolidated into a high-density pick zone, pickers spend less time walking and searching for items. The system automatically replenishes the pick face, eliminating downtime and boosting productivity. Together, these features help reduce labor, equipment wear, and fulfillment times.
Benefits include:
- Consolidated shelf space with defined SKU lanes
- Improved picking accuracy and speed
- Better visibility and access to inventory
- Ergonomic design for safer picking
Mallard’s Dyna-Flo HD carton flow rack features a full wheel bed design, allowing a variety of container sizes to be stored together on the same shelf—without gaps or wasted space. It’s a smart solution for facilities managing frequent SKU changes or diverse packaging.
Slim-Fit™ Full-Length Lane Dividers
Slim-Fit™ lane dividers are low-profile, full-length guides designed to define SKU lanes on a carton flow bed. Unlike traditional dividers, Slim-Fit™ locks securely into custom Mallard holders, preventing dislodging during high-activity picking or restocking.
The slim design and custom brackets allow for tight SKU lane configurations, with 0.170″ incremental adjustments to maximize shelf density.
Slim-Fit™ dividers also enhance overall system performance:
- Prevent lane drift, keeping SKUs aligned throughout the flow path
- Reduce wasted space between SKU lanes
- Enable quick SKU lane changes—quick, clip-in installation
- Available in five color options to support inventory color-coded picking
These dividers are especially valuable in operations with varied carton sizes or when optimizing for high-SKU-density pick faces.
Q&A: Your Carton Flow Rack Questions Answered
Q: Will Dyna-Flo HD handle both light and heavy cartons?
A: Yes! The system supports a wide range of weights—from 5 lbs up to 40 lbs—without performance issues.
Q: Can I mix totes and cartons in the same flow shelf?
A: You can, and we’ve tested it. Slim-Fit™ dividers ensure each SKU stays in its lane.
Q: What’s the benefit of using Slim-Fit™ lane dividers?
A: They eliminate wasted shelf space by customizing each lane to the exact carton or tote width.
Q: How can I get a test like this for my operation?
A: Contact our team to set up a custom test that mirrors your real-world conditions.
Discover the Carton Flow Rack Built for Manufacturing
Is your storage solution as efficient as a carton flow rack for your parts and finished goods? As this test proved, dynamic flow solutions adapt as quickly as your production floor does and provide the seamless operation your team needs to stay ahead of the competition.
Contact the Mallard gravity flow experts to explore our full range of carton flow, pallet flow, and custom gravity-fed rack systems. Let’s put the power of gravity to work for you and your team.
