Getting to the Middle of Carton Flow Rack Centers | Mallard Best Practices
SOLUTIONS
FOR THE TOUGHEST APPLICATIONS
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Tailoring Carton Flow Rack Centers to Your Product Depth and SKU Variety
Carton flow rack is a proven solution for improving order-picking efficiency, maximizing labor resources, and optimizing space in warehouses and distribution centers. They are ideal for full- and split-case picking, as well as individual items. Carton flow tracks are designed to fit within standard pallet racking—either as standalone units or as part of a pick module or tunnel. The tracks are installed on a slight pitch, allowing gravity to advance items from the loading (rear) side to the picking (front) side of the rack. This dynamic storage environment supports first-in/first-out (FIFO) inventory rotation, automatic pick-face replenishment, and improved SKU visibility.
With Mallard, your carton flow tracks are customizable to deliver the most efficient and cost-effective solution for your operation. From the type of rollers or wheels to the spacing between rows, each component can be tailored to your specific product mix. Whether you choose Cart-Trak roller tracks or Dyna-Flo wheeled tracks, Mallard offers a range of configurations to meet your unique application requirements.
Cart-Trak Roller Design Options: Widths & Spacing
The Cart-Trak roller system is ideal for operations with uniform carton sizes. It uses steel rollers in various widths and spacing configurations to provide full coverage and support for cartons and totes.
Roller Widths
- Available in 6″, 9″, 12″, and 16″ widths
- Choose a roller width that closely matches the width of your cartons or totes for optimal performance
Roller Centers (Spacing)
The spacing between rollers—called centers—is a key factor in maintaining consistent product flow. You can choose from 1″, 2″, or 3″ centers, depending on the depth of your cartons:
- 1″ Centers: Best for small cartons (3″ deep or greater); prevents sagging or tipping
- 2″ Centers: Suitable for mid-sized cartons (6″ deep or more); fewer rollers required
- 3″ Centers: Designed for larger cartons and totes (9″ deep or greater); most cost-effective for large, stable loads
Pro Tip: The deeper the carton, the more spacing you can allow between rollers without compromising product stability.
Dyna-Flo & Dyna-Flo HD: Flexible Solutions for Mixed Inventory
If your inventory consists of a mix of carton and tote sizes—or if you’re regularly changing SKUs—Dyna-Flo and Dyna-Flo HD are the way to go. These polypropylene wheeled track systems provide full-bed coverage, eliminating dead zones and ensuring smooth flow for all carton sizes.
Track Widths
- Available in 12″ and 16″ wide track sections
- Easy to scale across common rack bay widths (e.g., six 16″ tracks for a 96″ bay, add a 12″ track for 108″)
Wheel Centers (Spacing)
Dyna-Flo and Dyna-Flo HD tracks also come in 1″, 2″, and 3″ center configurations—just like Cart-Trak roller tracks. Choose your spacing based on the depth of your smallest carton:
- 1″ Centers: Ideal for small cartons under 5″ deep
- 2″ Centers: Work well for cartons 6″ or greater
- 3″ Centers: Recommended if your smallest carton is 9″ or more in depth
The full-bed wheeled design allows cartons and totes to overlap track sections without hanging up, making it a great choice for applications with non-uniform packaging.
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Add Slim-Fit™ Lane Dividers for Reprofiling or Compliance
Do you require SKU separation or frequently reconfigure your lanes? Our patent-pending Slim-Fit full-length lane dividers are the answer.
- Made from durable steel with a fold-over design that locks securely into place
- Feature mirror-imaged numbering and lettering on both the load and pick sides—great for two-person installation
- Maintain integrity during daily warehouse activity without becoming dislodged
These dividers complement any Dyna-Flo, Dyna-Flo HD, or Dyna-Deck installation, especially in operations with high SKU turnover or strict regulatory requirements.
Quick Installation & Rack Compatibility
Mallard roller and wheeled tracks are manufactured to drop into all leading rack manufacturers’ systems. That means:
- No complex adjustments
- Tracks can be quickly secured using tek screws
- A wide range of mounting bracket designs are available to suit your rack system
Simply select the product (roller or wheeled), desired center spacing, and compatible mounting bracket—and you’ve got a customized carton flow solution that’s quick to install.
Design Smarter for Smoother Flow
Choosing the right roller or wheel spacing isn’t just a technical detail—it’s a critical factor in creating a reliable, efficient, cost-effective carton flow system. With Mallard’s Cart-Trak, Dyna-Flo, and Dyna-Flo HD options, you can dial in the right design for your warehouse needs, whether you’re handling uniform cartons or a wide variety of SKUs.
Have questions about designing the ideal carton flow rack? Our gravity flow rack experts are ready to help you build a productive solution. You can also request a test in our interactive Engineering Lab to ensure your design is optimized for your inventory before finalizing your order.
Check out our YouTube Channel to see Cart-Trak & Dyna-Flo tracks put to the test!
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