Pallet Flow Rack Maintenance

Note: Do not attempt if your system has pallet separators—Skip to Step 4 for directions.

Start with the simplest method. Before removing the front pallet, try gently pushing it back to see if that prompts the rear pallets to flow. Follow these steps:

→ Lift the front pallet approximately 3 to 4 inches above the rails to clear the end stop
→ Slowing push back into the lane to bump the rear pallets gently
→ Withdraw the front pallet — this often frees the stuck load and restores normal flow

If the jam persists and there’s no visible cause (e.g., broken boards or plastic wrap caught on the rollers), try loading another pallet into the lane. Do not attempt if pallet separators are in the lane—skip to Step 4.

→ This added pressure may dislodge the stuck pallet and restart the flow.

If the pallet is still stuck after Steps 1 and 2, try loading additional pallets from the discharge end of the system.

1. Have a forklift operator load pallets from the discharge aisle until the hung pallet is pushed back into motion.

2. Assign a team member to monitor the lane and alert the operator as soon as the incoming pallet makes contact with the stuck pallet.

This method applies steady pressure from the opposite direction and can often free the jam without unloading the entire lane.

If all previous steps fail to release the jammed pallet, follow this process with extreme caution. This step involves entering the system, which should only be done by trained personnel under strict safety protocols.

Follow these steps:

1. Mark off the hazard area — both the charge and discharge aisles — to alert all nearby personnel and forklift operators.
2. Remove all pallets from the affected lane, starting with the most accessible.
3. Clear adjacent lanes to provide working space and improve access.
4. Fill the empty lane with empty pallets to create a safe, stable walking surface. The pallets must be snugly placed to prevent shifting during entry.
5. Enter the lane only from the load side, using all required fall protection or tie-off gear as specified by your facility’s safety procedures.
6. Inspect the lane to determine the cause of the hang-up — look for debris, pallet damage, product overhang, or component failure.
7. Manually downstack the load from the stuck pallet and lift out pallet if possible.
8. Inspect lane for damage, remove any debris, and recheck flow before returning the lane to service.

If damage to the lane or lodged debris is preventing pallet movement, contact a qualified technician or authorized professional to safely assess and resolve the issue.

• Log each inspection with time/date, findings, and resolution
• Note high-traffic or impact zones that may need more frequent checks
• Keep a record for internal safety and compliance reviews