Mistake-Free Pallet Flow Rack Design | Mallard Best Practices

“An ounce of prevention is worth a pound of cure.” ― Benjamin Franklin

Ben Franklin knew what he was talking about. As all of us battle to shave minutes off of processing time, there is literally no time for inferior and unreliable storage solutions. Mallard’s Gravity Flow Best Practices is here to help you get it right the first time, meet your needs, and optimize your efficiency when it comes to pallet flow rack design.

Designing a pallet flow lane begins with the inventory and pallet style that will be used in the system. The size, shape, style, load weight, and overhang all play a crucial role in what type of pallet flow product and accessories will be necessary for long-term, trouble-free use. Understanding how the different pallet flow products are applied to various pallet and inventory specs will help ensure your system design is right in line.

Pallet Flow Lane Load Capacity & General Use Guidelines

While pallet flow rack can be configured for a multitude of warehousing applications most fit within these general guidelines. Where an element of pallet, inventory specs, or use fall outside of traditional applications, the Mallard team is here to help you find the smartest products and lane design to meet your needs.

Skate Wheel Pallet Flow Rack

Steel Skate Wheel

Skate wheel pallet flow rack is an excellent cost-effective option for lightweight, shallow depth pallet storage (2-5 pallets deep).

Skate Wheel Specs:

• 50 -300 lb. wheel capacities
• 1.9” & 2.25” wheel diameters
• Inline and staggered rail options
• Rugged ball-bearing construction

Polycarbonate Wheeled Pallet Flow

Mallard offers two durable polycarbonate wheeled products. Magnum wheel is our signature pallet flow wheel for harsh conditions and heavy inventory. It is almost twice the width of standard polycarbonate wheels and has shielded bearings to withstand washdowns and be protected frost, rust, and debris. Magnum has a Lifetime Abuse Warranty. Industry equivalent (I.E.) wheeled rails are also available for standard applications. Talk to us about hybrid deep-lane solutions using Magnum and I.E. wheels for a cost-effective, durable pallet flow rack design.

Magnum Specs:

• Most durable pallet flow wheel available
• Ideal for heavy loads over 3,000 lbs.
• Ideal for freezer applications
• Lifetime Abuse Warranty!

Split-Roller Pallet Flow Rack

Roller Pallet Flow Rack

Steel rollers are often better suited for non-wood, non-standard pallet styles than wheeled rails. Plastic and metal pallets, for example, are better served with the broader surface area of split or full roller pallet flow. Additionally, rubber-coated speed controllers can be embedded in the lane to control the flow and prevent pallet surfing.

Roller Pallet Flow Rack Specs:

• 1.4”, 1.9”, 2.5” roller diameter options
• 90 – 350 lb. per roller capacity
• Between frame dimensions 4”- 60”

• Can be configured with pallet separator for full pallet or case pick applications

Split-Roller Pallet Flow

Split-roller rails are a very convenient option to flow non-standard pallets. Rails can be aligned with pallet surface for consistent contact. For extra-wide loads, split-roller rails can be positioned to support the load edge to edge to maintain tracking and consistent flow.

Split-Roller Specs:

• Non-standard GMA-style pallets
  • Heavy load weight
  • Footed or totally flat-bottomed pallets or containers
• Flange rollers can be added for pallet guidance
• Use with drop-in, direct mount or indirect mount speed controllers

Full-Roller Pallet Flow

Often a safe go-to for non-standard pallets and those benefitting from full surface coverage i.e., plastic, pod pallets, container or specialized pallets, corrugated containers or slip pallets. Full roller rails are available in widths up to 60” between frames which allows for a broad variety of pallet widths both smaller and larger than standard the standard 48” x 40” size. It can also serve as a universal pallet flow lane for applications where multiple pallets of varying sizes are used.

Full Roller Specs:

• Non-standard GMA-style pallets
• Varying pallet sizes in one application
• Use with Ultra-Grip rollers paired with indirect mount speed controllers for ideal pallet control

Important Cautions

Avoid Under Designing to Save a Buck

A pallet flow lane that is under-designed will struggle under the repeated use of pallets that are too heavy or perhaps load unbalanced. Even good quality wheels will strain and fail. Money “saved” in using two rails instead of three is lost in downtime and repairs.

Full Roller with Ultra-Grip Speed Controllers

Eliminate Back Pressure with Pallet Separators

Pallet separators are designed to put a gap between the front, pick aisle pallet, and the rear pallets. The gap eliminates the pressure of the rear pallets bearing down on the front pallet. Without the rear pallets butted up against the front pallet, it is easier and safer to extract that pallet. The deep the lane, the heavier the pallets the more important it is to control that backpressure. Mallard has engineered a pallet separator for each unique pallet flow product and application to provide seamless and safe operations. See our product brochure or call our team for advice and support.

When in Doubt Test it Out

Mallard offers our in-house testing lab services free of charge prior to ordering. It is the ideal spot to examine the pallet flow or carton flow lane design with customer-supplied inventory and pallets/containers to ensure that the system is optimally configured. Customers receive a test video and printout with recommendations and/or confirmation of system specs.

Mistake-Free Services Just a Phone Call Away

Let the Mallard team help you configure the best pallet flow rack system for your unique warehousing circumstances. Our products are as tried and true as our commitment to ensuring the best solution and customer experience. Call today for application advice and pricing and be sure to sign up for our monthly newsletter to receive helpful advice about all things gravity flow rack.

Visit our YouTube Channel for pallet flow, carton flow, and gravity conveyor rack instructional videos.

For more information check out: 5 Signs It’s Time to Replace Your Pallet Flow System.