Maximize Pick Efficiency with Smart Storage Powered by Gravity Flow Rack
Smart Solutions for Retail Distribution
Accelerate pick rates, improve stock visibility, and adapt to your evolving product mix. It’s not just organized storage—it’s momentum engineered for modern retail warehousing.
Mallard’s gravity flow rack systems support a range of retail warehouse demands—from high-density storage to fast-moving pick zones and dock staging. From full pallets, mixed-SKU orders, or small-package picks, each system is engineered to maximize throughput and minimize touchpoints.
Gravity Flow Rack Applications
- Multi-Level High-Density Rack – Palletized inventory 2 to 20+ deep
- High-Volume Case & Tote Storage – Ergonomic, concentrated pick zones
- Mixed-SKU Pallet Building – Efficient layer and case picking
- Fast-Turn Case Picking – Pick from pallets with automatically replenished pick faces
- Dock Intake & Outbound Staging – Safe, organized dock staging to reduce forklift congestion
High-Density Pallet Storage
Carton Flow Rack
Floor-Mounted Flow Lanes
How It Works:
Gravity flow solutions use roller or wheeled tracks pitched at a slight angle to move inventory. As items are picked, stock automatically flows forward to fill the pick face. With loading and picking on opposite sides, these systems support concurrent activity—streamlining labor resources and eliminating wait time for replenishment.
SKUs are organized by lane and can be installed in multi-level rack systems or mounted directly to the floor.
These systems are a great fit for retail operations that need flexibility, dense storage, and quick access—whether you're working with short runs or deep-lane setups that rival ASRS systems.
Ready to Optimize Your Retail Warehouse?
Call our team for a thorough assessment and a gravity flow rack solution that solves your retail warehousing challenges.
Pallet Flow Rack – Multi-Level High-Density Rack
Magnum Wheel 10-Deep Pallet Flow Rack
Mallard’s pallet flow rack systems control FIFO inventory for large volumes of palletized items such as home goods, electronics, and boxed apparel. The deep-lane storage keeps replenishment stock at the ready in orderly SKU lanes, eliminating wait times and supporting fast, accurate picks.
Key Features
- Ideal for high-volume SKUs--seasonal stock, clothing, specialty goods, small appliances
- Accommodates standard & non-standard pallets
- Customized to your pallets & load specs
- Available in full- or split-roller, and wheeled configurations
Building a Pallet Flow Lane - Rollers vs. Wheels
Roller Design Options
Choose full- or split-roller lanes for systems handling plastic pallets or varied pallet sizes—ideal for SKUs that change frequently or operate outside standard formats. Rollers are available in several diameters and lengths to satisfy all inventory requirements.
Unlike Drive-In racking, roller lanes allow mixed pallet types within the same system for greater flexibility and streamlined storage.
Wheeled Options
For heavier applications, our Magnum wheel offers unmatched durability and impact resistance… and it is backed by a Lifetime Abuse Warranty!
The M-150 wheel provides a reliable, cost-effective solution for standard or moderate-capacity loads. Magnum and M-150 wheels are wider than industry-standard wheels, providing better traction and load support for 3000+ lbs.
Steel skate wheel lanes are also available—ideal for 2- to 5-deep pallet flow applications and pallet loads up to 2,000 lbs.
All Mallard wheeled pallet flow systems deliver smooth, consistent pallet movement with minimal maintenance, tailored to your inventory and throughput needs.
Customized to Meet Your Inventory Flow Needs:
Every Mallard pallet flow rack system is engineered to your specific inventory profiles, volume, and throughput needs—ensuring your space works as hard as your team. All Mallard products are proudly manufactured in the U.S.A.
Carton Flow – High-Volume Case & Tote Storage & Picking
Carton Flow Rack
Carton flow rack is your go-to for high-volume SKUs fulfilled by the case—whether to brick-and-mortar stores or direct-to-consumer customers. With the ability to stock and pick simultaneously, productivity stays high, even during peak seasons.
Carton flow shelves handle uniform or varied box sizes, totes, and containers in organized SKU lanes, enhancing visibility and picking accuracy. The consolidated design reduces worker travel and boosts pick rates, yielding up to 75% labor savings. These systems also integrate seamlessly with pick-to-light and automation technology to drive even greater throughput.
Key Benefits:
- Design options -
- Wheeled shelf for variable-size containers
- Roller lanes for same-size cartons, totes, or boxes
- Handles folded apparel, boxed electronics, accessory kits, or specialty goods
- Optional Accessories – Boost ergonomic comfort and long-term performance
Flexible Integration for New or Existing Rack:
Carton flow lanes are easy to install in standard pallet racking. Converting underutilized lower rack levels into high-density carton and case storage can transform your picking operation.
This simple retrofit adds speed and SKU access without sacrificing vertical storage. Alternatively, carton flow can be deployed in standalone rack systems to create dedicated pick zones that support conveyor-fed inbound and outbound inventory flow—ideal for high-volume fulfillment and sortation lines.
Let's take a look at your space and picking needs and design just the right solution to achieve your throughput goals.
Gravity Flow is on the Case for Case Picking Efficiency
In high-velocity retail environments, floor-mounted pallet flow lanes deliver smart, efficient case picking and mixed-SKU pallet building. Supporting either hand-picking for smaller store replenishment or robotics for high-throughput operations, gravity flow rack streamlines the process to produce big results.
Hand-Picked Mixed-SKU Pallet Building
Floor-mounted pallet flow lanes position palletized SKUs in an easy-to-access layout for fast, ergonomic case picking. Operators quickly pull from multiple lanes to build mixed-SKU pallets for store replenishment or planogram-specific loads, reducing travel time and simplifying downstream handling.
Benefits:
- Safe for concurrent load, pick, and takeaway functions
- Compatible with powered conveyor for takeaway
- Ideal for apparel, home goods, and specialty retail shipments
High-Throughput Layer Picking with Ergo Build
Mallard’s patent-pending Ergo Build solution significantly boosts productivity and slashes labor costs for high-throughput mixed-SKU pallet building. This is your way to streamline pallet building and simplify pallet takeaway to support high-throughput mixed-SKU pallet building activity. Pairs with semi- or fully-automated pick equipment.
Ergo Build Benefits:
- Labor reduction up to 11 to 1 vs. hand picking
- 4-5 times less expensive than the alternative powered conveyor solution
- Continuous workflow – streamline center aisle picking, shift pallet takeaway to outside aisle
- Significantly increase FIFO throughput
Whether building by hand or machine, Mallard’s floor-mounted pallet flow systems deliver the flexibility, control, and efficiency retailers need to stay competitive. Contact our team for a quote.
Every Mallard gravity flow rack system is engineered to perform, and our gravity flow rack experts can also test your system before finalizing your order. Our state-of-the-art, interactive Engineering Testing Lab tests your pallets, cartons, and sample inventory to ensure optimal performance from day one. Contact our team today to explore all the ways that gravity can work for you.
Dock Intake & Outbound Staging:
Smoother Transitions. Faster Turnaround.
Before
After
Eliminate congestion, improve visibility, and keep goods flowing from the dock to the pick face.
At the intersection of inbound and outbound logistics, dock staging is where retail distribution can either flow—or falter. Mallard’s pallet flow racking and gravity conveyor systems bring structure and control to this critical zone, reducing forklift traffic and ensuring inventory is always where it needs to be, when it needs to be.
Our systems provide:
- First-In/First-Out (FIFO) flow to maintain product integrity and freshness
- Dedicated staging lanes for organized separation by route, customer, or product type
- Flexible designs that integrate with automated systems or manual operations
- Fork-free product movement to reduce accidents and labor demand
Whether you’re staging for outbound shipment or buffering inbound goods before slotting, Mallard’s gravity-fed solutions bring discipline and efficiency to your dock areas—keeping your operations nimble and retail-ready.
