Sterling, IL, February 7th, 2023 – Mallard Manufacturing, leading gravity flow storage systems provider, launches space and labor-saving layer pick solution for mixed-SKU pallet building —Ergo Build with pallet flow. Unlike traditional layer pick applications, Mallard’s semi-automated Ergo Build lanes combined with pallet flow consolidates layer picking activity within a single aisle, boosting pick rates and safety while reducing downtime.

How it Works

• Reverse flow lanes equipped with Ergo-Build pallet separators are interspersed with pallet flow lanes
• Pallet flow lanes feed pallets toward the layer pick aisle
• Forklifts (using layer pick attachment) pick carton layers to build rainbow pallets on the Ergo-Build lanes
• The Ergo-Build pneumatic pop-up separator holds the rainbow pallet in place at the pick aisle until the forklift operator presses the remote release button
• Once released, the complete rainbow pallet flows to the opposite aisle for pickup

“Ergo Build with pallet flow maximizes layer picking and mixed-SKU pallet building efficiency, delivering continuous productivity for facilities with high-volume order fulfillment. Since its release, we’ve already seen Ergo-Build transform pallet building in the beverage sector and we’re excited about the impact across grocery, automotive, and retail sectors,” says Kevin Risch, President of Mallard Manufacturing.

Watch Ergo Build at work in the animated video below.

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