How to Optimize Ergonomic Case Picking with Controlled Flow and Better Access

Give Your Team a Lift—And Your Case Pick Productivity, Too

High-volume case picking is a demanding operation. Between inconsistent pallet styles, heavy loads, and the strain of repetitive motion, it’s easy for efficiency to slip—and for operators to feel the impact.

This recent test from the Mallard Engineering Test Lab offers a focused, manageable solution: combining the Ergo Cell pneumatic pallet separator, Magnum Wheel pallet flow, and a hydraulic lift table to streamline the pick process and ease the physical demands on warehouse teams.

Designed for a major warehouse club retailer, the system was tested under mixed pallet conditions to reflect the challenges many operations face daily. 

The result? Controlled pallet flow, ergonomic access, and efficient picking—without back pressure, excessive reaching, or bottlenecks.

Ergonomic Case Picking: Spin & Pick at the Pallet Discharge Zone

Pallet Flow Rack for Ergonomic Case Picking

This test setup was built to validate a simple premise: Can we improve high-volume case picking by combining ergonomic tools with smart pallet flow design? The answer? Yes—and here’s how:

Test Overview:

• Pallet Load Weight: 270–440 lbs
• Pallet Types: Plastic and wood (CHEP, PECO), 40″ x 48″
• Lane Length: 14.5 ft
• Pitch: 7/16” per foot
• Speed Control: Direct-mount controllers at 56” spacing
• Flow Lanes: 3-rail Magnum Wheel pallet flow
• Pallet Separator: Ergo Cell with lift table

The Magnum Wheel flow lane is configured with two full-length outer rails and a shorter center rail. That shortened center rail creates an intentional opening at the front of the lane—the ideal space for a hydraulic lift table. The Ergo Cell separators are positioned on either side of the shorter center rail.

Step-by-Step: Ergonomic Case Picking in Action

Ergo Cell Separators in Mallard Pallet Flow Lane

1. Pallets are loaded into the flow lane, which features two full-length outer Magnum Wheel rails and a shorter center rail to accommodate the lift table at the discharge end.
   
2. Gravity advances the pallet smoothly down the lane. The lead pallet is stopped just short of the lift table by the front Ergo Cell separators.
   
3. The operator presses the pedestal-mounted control button, triggering the Ergo Cell system.
               a) The front separators drop down, allowing the pallet to advance onto the lift table.
               b) Simultaneously, rear separators rise to hold back the next pallet.
   
4. The pallet is centered on the lift table. Using a foot pedal, the operator raises the table above the rollers and end stops.
   
5. The table spins freely, giving the picker 360° access to all sides of the pallet—eliminating the need for reaching, bending, or twisting.
   
6. Once picking is complete, the emptied pallet is removed from the lift table, and the table is lowered (if needed).
   
7. The operator presses the control button again, releasing the rear pallet to move forward into position.
   
8. The Ergo Cell’s timed sequence ensures that rear pallets do not interfere with raising or lowering the lift table, maintaining both safety and flow control throughout the process.

Why It Works

• Controlled flow: Pneumatic separators manage pallet indexing precisely.
• Ergonomic access: Lift table raises and rotates the pallet for optimal pick conditions.
• Pallet versatility: Magnum Wheel lanes handle plastic and wood pallets with ease.
• Operational safety: Built-in flue space and no back pressure for easy picks and pallet removal.

Magnum Wheel pallet flow provided the smooth, consistent movement needed for ergonomic case picking—particularly valuable with mixed pallet types.

Learn more about Magnum Wheel pallet flow.

Together, these components form a complete ergonomic case picking solution—minimizing strain, maximizing access, and keeping high-volume picking operations moving safely and efficiently.

Why This Matters to Warehouse Operators

At Mallard Manufacturing, we bring 60+ years of expertise to every gravity flow system we design. Our in-house engineering and interactive test lab ensure you get tailored, power-free solutions that improve warehouse performance.

If you’re dealing with high case volumes, mixed pallet inventory, or looking to improve ergonomic conditions in your warehouse, this test proves that Mallard’s Ergo Cell + Magnum Wheel pallet flow combination is up to the challenge.

You get:

• Efficient pallet flow with controlled indexing
• Better worker ergonomics and safety
• Scalable design for any picking environment

Ready to optimize your case picking process? Contact the Mallard Team.

Want to see more in action? Browse our YouTube Channel.