New Pallet Separator Enhancements Expand Pallet Flow Rack Performance

Application-driven pallet separators boost speed, safety, and smooth flow for pallet flow rack.

We’ve recently enhanced our pallet separator product line to address broader pallet flow rack application needs. As you’ll see in our newly updated brochure, our pallet separators not only effectively remove back pressure on the front pallet for safer, easier removal, but can also be used to add pallet separation downlane in deeper systems. 

Whether you’re picking cases by hand, or using AGVs, robotic pickers, or traditional forklifts, Mallard separators ensure a safer, faster, and pressure-free pick experience.

Understanding the Role of Pallet Separators in Pallet Flow Rack

The primary function of a pallet separator is to remove the combined back pressure on the front pallet from the rear pallets due to the pitched flow lane. Separators enable safer, efficient picking by isolating the lead pallet.

The formula for calculating back pressure is:

06 x (pallet load weight) x # of pallets behind the front

For example, in a 3-deep system with 2,500 lb loads, back pressure would equal:

 .06 x 2,500 x 2 pallets = 300 lbs of excess pressure. 

In a 20-deep system with 2,500 lb loads, back pressure could soar to:

 .06 x 2,500 x 19 pallets = 2,850 lbs of excess pressure. 

Separators can also be used in deeper-lane systems to create a controlled gap between pallets. This simple yet effective tool improves safety, boosts picking productivity, and supports overall system performance—all in one motion.

If you’re unfamiliar with current fire/insurance spacing practices in deep-lane storage, note that requirements vary by jurisdiction and carrier. Pallet separators can help establish the controlled gap/flue space many facilities need, but final criteria should be confirmed with your local fire marshal or building/code inspector and insurer.

Quick Benefits of Using Pallet Separators:

• Eliminate back pressure on the front pallet in pitched flow lanes
• Improve worker safety
• Ensure controlled pallet gapping in deep pallet flow lanes
• Enable quick, smooth pallet clearing

Download our pallet separator brochure for full specs, layouts, and compatibility info.

From Case Picking to Layer Building—We’ve Got You Covered

Case Pick Separator	Forklift Separator	Layer Pick Separator

No matter the application—case picking, pallet building, or full pallet storage—Mallard has a separator solution engineered to fit your pallet flow system. 

Here’s a quick look at the full range before we highlight our three updated models.

Three of these products have recently been updated to better meet today’s inventory demands. Let’s take a closer look at these enhanced solutions and how they help your warehouse flow more efficiently than ever.

Case-Pick Separator – Designed for Picking by Hand

When speed and safety are the priorities, the Case-Pick Separator delivers. It isolates the front pallet, allowing pickers to remove empty pallets quickly—unimpeded and completely pressure-free.

A simple foot-tap release brings the next pallet forward. It’s designed for 2–4 deep pallet lanes. When properly configured, the case-pick separator can also support AGV and robotic case picking.

Case-Pick Separator Highlights:

• Boosts case-pick productivity
• Helps prevent strain injuries during manual pallet removal
• Raised design allows cleaning underneath
• Not for forklift use
• Can be configured for AGV and robotic case picking

Use with GMA, CHEP, or other pallets with cross boards in lanes with depth from 32″–48″… maximum four pallets deep.

Forklift Separator – High-Density Storage Applications

Mallard’s Forklift Separator series is engineered for deep-lane, multi-level pallet flow systems. It provides automatic pallet gapping to eliminate back pressure at the pick face. As soon as the lead pallet is cleared, rear pallets release automatically and advance to keep inventory flowing smoothly and safely—no delays, no back pressure.

Upstream & Downstream Forklift Separator Designs

Mallard’s Forklift Separator Series includes downstream (latching) and upstream (non-latching) models that can be used individually or together, based on the operational needs of the flow lane.

• Downstream (Latching): Holds back rear pallets until the lead pallet is removed. This design prevents back pressure at the pick face, protects forklift operators from mast strain, and enables safe, efficient pallet change-outs at elevation.
• Upstream (Non-Latching): Releases automatically as pallets advance through the system, maintaining flow and spacing without manual resets.

Used together, these designs isolate the pick-face pallet, eliminate back pressure, and help facilities meet fire code spacing requirements while optimizing throughput in high-density, deep-lane storage systems.

Forklift Separator Advantages:

• Automatic gapping between pallets
• Eliminates back pressure on front pallet
• Designs compatible with wheeled, full roller, and split-roller flow lanes
• Can be integrated with AGVs

Use with GMA, CHEP, or other pallets with cross boards in lanes with depths from 32″ to 48″; a 12″ gap is required.

Layer Pick Separator – Speed Meets Flexibility for Mixed-SKU Orders

Designed for layer-picking applications, the LP Separators streamline mixed-SKU pallet building. Used in high-volume mixing centers or staging areas, this solution is built for floor-mounted flow lanes that feed inventory to the pick aisle. The LP Separator isolates the front pallet so the layer-pick equipment can surround and select the cases. 

Once the empty pallet is removed from the lane, the rear pallets automatically release, flow forward, and fill the pick-aisle position, keeping activity moving without delay.

Layer Pick Separator Advantages:

• Simplifies empty pallet removal
• Improves throughput in high-volume layer pick operations
• Auto-advances rear pallets—no restocking delays
• Configurable for forklift attachment or robotic arm picking

Use with GMA, CHEP, or other pallets with cross boards in lanes with depth from 32″–48″, max 4 pallets behind the rear paddle

Safer, Faster Flow Starts Here

Layer Pick Aisle with EB & LP Separators

From pallet spacing to faster, safer picking, Mallard’s pallet separators improve operational flow and safety. Our team will help you choose the right separator, provide design support, and test with your pallets and inventory to validate performance before you commit—so you get a pallet flow rack solution that’s right the first time.

Here’s how we can help:

• Application guidance & direction tailored to your inventory and processes
• Engineering/design support for lane layout and separator placement
• Hands-on testing with client-supplied pallets and product to confirm flow, release, and performance

Let’s get started. Contact the Mallard team for information or request a quote.

Visit our Resources page to download the updated Pallet Separator Brochure and view product videos.