Double-Stacked Crates Flow Steady on Full Roller Rack

Specialty Speed Controllers Prevent Plastic Crates from Surfing on Full Roller Rack 

Full roller pallet flow rack is most often the best choice for plastic and metal pallets and crates. Full roller provides full-width coverage to make the most consistent contact with the bottom of the pallet or crate, no matter if it has runners, pod feet, or rails. The rollers are galvanized and manufactured to the highest standards, using heavy-duty bearings, axles, and side-channel to handle heavy pallet loads effectively.

Speed Controller Combo Controls the Flow

One consideration is that plastic and metal pallets can tend to surf over the galvanized rollers. Rubber-coated Ultra-Grip speed controllers added to the lane help the pallets maintain consistent and safe flow speeds. Ultra-grip rollers are often used in pairs and are available in the same diameters as our full roller rack -1.9” and 2.5” for a seamless drop into the flow lane.

With heavy loads or stacked loads, however, the Mallard team often recommends adding one more safety measure, and that is our Field Installed Brake Assembly or FIBA. The FIBA assembly is our indirect mount speed controller mounted in a frame that allows easy installation in the… you guessed it… the field. The FIBA speed controller mounts underneath the Ultra-Grip roller pair.

Watch Ultra-Grip and Full Roller Rack in Action

Do you think that all that sounds great, but you want to see how it all works? Well, take a look at our test video to watch full roller with Ultra-Grip and FIBA speed controllers control 700 lb. stacked plastic crates.

Full Roller Pallet Flow System Design

• 1.9” diameter full roller on 2” centers
• Ultra-grip rollers
• Indirect mount speed controllers
• ⅜” per foot pitch
• Bolt-on ramp stops
• Crate Dimension – 40″w x 48″d
• Load – 700 lbs. / 1400 lbs. Double stacked

As you can see, the crates flow consistently down the lane. The stacked crates are steady and progress at a safe speed. Even with a broken runner on one of the crates, the pallet flow lane design effectively controls the flow and tracking.

What Pallet Flow Lane Will Work for You?

The Mallard team is available to help you configure your pallet flow lane to best suit your inventory and processing needs. Every warehouse is unique, and equipping your gravity flow rack for your unique inventory and pallet specs will ensure long-term success. Call our flow rack experts today for design guidance and system testing before finalizing your order.