Case Picking Made Easy: Pallet Flow Test Highlights the Power of “Ergo Cell Ergonomics”
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Smoother Case Picking for High-Volume Retail: Convenience Just Got an Upgrade
If you’re managing a high-volume distribution center—especially for convenience store chains—you know the strain that case picking can put on both your team and your equipment. Mallard’s Engineering Test Lab recently put one of our most efficient gravity flow configurations to the test: combining our Ergo Cell pallet separator and a hydraulic lift table for high-efficiency case picking from pallet flow rack.
The results? An ergonomic, high-throughput solution that controls pallet advancement and reduces strain on pickers. Here’s how it works—and why your team will thank you.
Engineering Test Configuration: Built for Real-World Warehouse Challenges
Our state-of-the-art testing center is the ideal spot to simulate a real distribution environment. The sample test lane consisted of:
- 3-rail wheeled pallet flow lane
- 2″ wheel centers for dense support
- Speed controllers: Direct mount at the forward hold-back position and drop-in controllers spaced 56” apart along the lane
- Pitch: 7/16” per foot
- Load weight: 200 – 1080 lbs.
- Pallets: 40″ x 48″ wood—varied in condition (warping, protruding nails, live edge boards)
Key components included:
- Ergo Cell pneumatic pallet separator
- Hydraulic lift table for ergonomic pick height adjustment
This system mirrors what’s often found in distribution centers, where workers case-pick directly from palletized inventory… often to a takeaway conveyor.
Smart Flow Control with Speed Controllers and Ergo Cell
One of the biggest takeaways from this test was the system’s ability to handle pallet flow and indexing effectively, despite the challenging pallet conditions.
✔ Controlled Flow – The pitched flow rails promote safe, consistent pallet movement
✔ Isolated Front Pallet – The Ergo Cell pop-up separators hold back the second pallet in the lane until the front pallet (on the lift table) is removed.
✔ Indexing Made Easy – As each pallet is cleared from the lift table, workers simply tap the pneumatic control to release the rear pallets to flow forward and automatically fill the front lift table position again.
This setup isolates the front pallet, allowing it to flow onto the lift table to rise up to a better ergonomic position for case picking—rear pallets release when the front position is clear and the worker is ready.
Pallet Quality Matters—But the System Adapted
The five customer-supplied pallet samples used in testing weren’t ideal. They had:
- Slightly warped boards
- Broken slats
- Protruding nails/staples
- Uneven deck thicknesses
Ideally, you want pallets in good condition to ensure the pallet makes consistent contact with the wheels and speed controllers. The better the contact, the more controlled and, therefore, safer the flow.
Despite these flaws, the system still performed well with minimal hang-ups. If the customer experiences minor pallet restart issues once installed, simply loading an additional pallet into the lane should remedy the hang-up and advance flow.
Along with evaluating pallet samples, our team recommends implementing pallet inspection training for warehouse teams. It’s always better to avoid putting compromised pallets into the flow lane.
Check out our Everything About the Pallet blog for a deep dive into pallet styles and quality best suited for your pallet flow rack applications.
Ergonomic Advantages: Better for Your Team, Better for Productivity
Lift Table Rises to Ergonomic Picking Height
Adding a hydraulic lift table to the pallet flow lane design significantly improves operator comfort. Workers can adjust the table to an ideal pick height throughout the case pick process, reducing strain and repetitive motion injuries.
Ergonomic highlights:
- Reduces operator fatigue
- Minimizes bending/lifting injuries
- Improves pick accuracy and speed
Combined with the Ergo Cell, the system reduces picker downtime and enhances throughput, particularly in fast-paced distribution environments.
At Mallard Manufacturing, we don’t just build pallet flow systems—we test them, refine them, and tailor them to your application. From design support to onsite consultation, our team is here to help you optimize your space, reduce strain on your team, and keep your operations flowing smoothly.
Let our gravity flow experts help you optimize your case picking application. Explore our pallet flow rack systems or reach out to schedule a consultation.
