Maintaining Your Push-Back Rack System: Mallard Best Practices

Top 5 Maintenance Tips to Extend the Life of Your Push-Back Rack System

If you’re relying on your push-back racking system to keep your warehouse moving efficiently, it’s essential to understand how simple maintenance can extend system life and prevent costly downtime. Whether you’re using our shallow-depth cart system or the high-density push-back flow rack, following these best practices ensures optimal performance and uptime.

Meet the Mallard Push-Back System Lineup

Mallard Manufacturing offers two types of push-back rack systems, each uniquely engineered for long-term, low-maintenance use:

1. Shallow-Depth Push-Back Cart System (up to 3 pallets deep)

Mallard’s shallow push-back cart rack is a low-profile, high-performance solution for facilities seeking quick access and minimal system wear. This design is especially suited for LIFO (Last-In, First-Out) inventory strategies where rapid turnover is essential. How It Works Pallets are loaded and unloaded from a single aisle. The first and second pallets are placed on top of the carts that stack at the front of the lane. The first pallet is placed on the top cart. To load pallet two, the first pallet is pushed back deeper into the lane, exposing the cart underneath. Pallet three sits directly on the rails and doesn’t require a cart. When unloading, gravity flows the rear pallets forward to the pick face.

Key Components Wheeled Tracks: Heavy-duty, precision-aligned tracks guide pallet movement. Unlike standard systems, Mallard’s wheeled tracks are more resilient and easier to clean. Custom Carts: Instead of traditional wheeled carts, Mallard uses carts without integrated wheels to reduce wear, eliminate pinch points, and simplify maintenance. System Advantages Fewer Moving Parts = Less Maintenance: With wheel-less carts gliding on wheeled tracks, the wear points are reduced and easier to monitor. Lower Profile: A space-saving design for locations with height restrictions or fast-moving SKUs. High Turnover Ready: Perfect for operations needing frequent pallet changeover without sacrificing selectivity or floor space.

2. Push-Back Flow Rack (up to 12 pallets deep)

For warehouses needing to store more while using less aisle space, Mallard’s push-back flow rack offers a reliable, low-maintenance solution for warehouses needing to store more while using less aisle space. This cart-free system uses gravity to smoothly flow pallets forward for retrieval—ideal for deep-lane, high-density, Last-In/First-Out (LIFO) applications.

Key Components Gravity Flow Rails: Full-length, heavy-duty rails guide pallet movement with precision and minimal friction. Wheel & Roller Options: Choose based on load weight, pallet condition, and environmental demands: Steel Skate Wheel – Lightweight applications, shallow lanes Polycarbonate M-150 Wheel – General-purpose durability Magnum Wheel – Heavy loads, freezer, or harsh environments Roller Tracks – For plastic or non-standard pallets needing broader contact System Advantages Up to 12 pallets deep: Greater lane depth for LIFO applications compared to cart systems Pallet flexibility: Can accommodate non-uniform pallet sizes Simplified maintenance: Fewer components mean less wear and fewer service points High-load capacity: Can be engineered to accommodate significant pallet load weights These solutions are engineered to reduce maintenance demands, but proactive care is still key.

Routine Maintenance Best Practices for Push-Back Racking

While Mallard’s push-back systems deliver long-term durability and low maintenance, routine inspections and small daily habits go a long way in ensuring optimal system performance and safety. Here are 5 Tips to keep your system running smoothly:

1. Inspect for Debris Regularly

Broken pallet boards, exposed nails, and loose plastic wrap can accumulate inside the rack lanes. Left unchecked, this debris can interfere with pallet movement or damage flow components, leading to costly downtime or emergency repairs. Sharp objects like nails or splintered wood can gouge or chip the flow rails, accelerating wear and requiring replacement.

Encourage forklift operators or warehouse staff to perform a quick pallet inspection before loading. Look for pallet damage, dangling plastic wrap, and loose inventory that can dislodge and disrupt flow. Spending just a few extra seconds per load can prevent hours of unplanned downtime.

2. System Component Inspection

Nesting Carts
Check carts for visible wear, including dents, cracks, or loose hardware. While Mallard carts are wheel-less, ensure their surfaces glide cleanly along the wheeled or roller tracks. Verify that the carts return and envelope at the pick face after unloading.

Flow Rails & Wheels
Inspect wheels and rollers for cracks, chips, or flat spots that could disrupt pallet movement or stress the rack structure. Ensure all wheels spin freely and show no signs of obstruction. Similarly, check that flow rails are clean, straight, securely fastened, and properly aligned to support consistent, unobstructed pallet flow.

Uprights & Structural Integrity
Ensure rack uprights are plumb, anchored, and structurally sound. Look for signs of impact, bending, or baseplate damage. Any shift in upright alignment can lead to flow irregularities and create unsafe loading conditions.

3. Aisle and Pathway Clearance

Aisles
Keep all forklift aisles clear of obstructions. Stacked items, wrap, or debris in the aisle can interfere with operator visibility and safe pallet loading. Clear aisles improve precision and reduce the risk of side-impact rack damage.

Pathways
Ensure all access routes to and from the racking system are clutter-free. This allows for efficient forklift travel and helps minimize the risk of accidental impact or blocked access during high-volume shifts.

4. Use Quality, Undamaged Pallets

Pallet condition directly impacts flow performance and system longevity—avoid softwoods and compromised pallets. Broken boards, exposed nails, or splintered wood can snag on flow components, resulting in misaligned carts, stalled pallet movement, or even system damage.

Always use structurally sound pallets capable of supporting the full load uniformly across the entire pallet surface to prevent sagging or point loading. Adding wire decking on top of the cart is an effective way to minimize sag and distribute weight more evenly. Point loading is a critical concern—it can cause the pallet to drift off-center within the lane, leading to a hang-up or inconsistent flow.

5. Train Forklift Operators on Proper Loading

Improper loading techniques are a leading cause of push-back system issues. Forklift operators should load pallets straight and evenly—never at an angle—to prevent misalignment and unnecessary strain on carts or rails. Avoid using excessive force to drop pallets onto the carts or rails, as this can damage both the pallet and the rack system. Emphasize slow, controlled loading and unloading to extend the life of all system components and maintain consistent flow.

Signs It’s Time for a Closer Look

If you notice any of the following, it’s time to pause and inspect:

• Uneven pallet flow or sticking carts
• Repeated hang-ups at the same lane position
• Increased resistance during unloading
• Visible wheel/roller or track wear

Even with Mallard’s rugged designs, these are cues that a quick tune-up could prevent a more serious issue.

Keep It Clean, Keep It Straight, Keep It Flowing

Push-back racking offers a space-saving, time-saving warehouse solution—but like any high-performing equipment, it needs a little TLC.

Following these simple maintenance steps, you’ll ensure your Mallard push-back system continues to deliver safe, efficient, and long-lasting performance—exactly what we design for.

Contact the Mallard team for more information and a quote!

At Mallard, we don’t just sell gravity flow rack—we build smart systems that work as hard as you do. Our engineering team is always ready to help troubleshoot, offer system evaluations, and suggest upgrades for aging systems.

Related Resources – Recent Pallet Rack Retrofit Projects:

Maximize ROI with Push-Back Rack: A Drive-In Retrofit Success Story

Push-Back Flow Rack Goes Full Roller Retro in Two Recent Installations!

Visit our YouTube Channel for System Tests and Design Support