Pallet Flow Racking Passes the Round Pallet Test

Test Results Confirm Pallet Flow Racking Can Handle More Than Just Traditional Loads

We’ve seen a lot of unique products tested in our in-house Engineering Testing Lab—but this may be a first. Recently, we were asked to test circular wooden pallets for a new pallet flow racking storage system. Yep, round pallets. The big question? How well would they flow?

The answer: surprisingly well—and here’s why it worked.

What is Pallet Flow Racking?

If you’re new to pallet flow rack, here’s a quick overview of this gravity-fed storage solution. Pallet flow systems are engineered to increase warehouse efficiency by consolidating pallet storage into multi-deep lanes, loaded from one aisle and picked from the opposite. Each lane is built with slightly pitched rollers or wheels, allowing pallets to move forward automatically as the front pallet is removed, delivering a reliable first-in/first-out (FIFO) inventory rotation.

Pallet flow is ideal for high-volume SKUs, and you’ll often find it in manufacturing and distribution environments for storage of raw materials, finished goods, or both. The system reduces travel time, maximizes space, and ensures efficient product access—all without powered equipment.

Round Pallets? Here’s What We Learned from the Test Now, back to the testing lab.  Our engineers configured a custom pallet flow lane based on the specifications provided by the system design team. Using five client-supplied circular pallets, we ran a full functionality test, evaluating both the pallet design and lane performance to ensure consistent, controlled flow.

Flow Test Results:

Despite the unusual shape, the pallets performed well.

• Pallets flowed smoothly down the lane.
• FIBA speed controllers effectively managed descent.
• No hang-ups during unloading.
• Forklifts could remove pallets cleanly

What Made the Round Pallets Work? Although the pallets were round, the center board extended slightly beyond the circular top—a key design feature that provided a flat touch point between the pallets. This helped keep them aligned in the flow lane without hanging up on one another and also ensured clean lift by the forklift, eliminating rear pallet drag. The takeaway? Even non-standard pallet designs can perform effectively in a gravity flow system when paired with the right flow lane configuration.
	Flow Rack Test Tips & Watch List No matter the pallet shape, these fundamentals apply: Inspect wood pallets for damage before use—broken boards or protruding nails/staples can interfere with smooth flow. Use the plugging method to resolve any minor hang-ups during discharge. Always test your pallets in our Engineering Lab to ensure safe, effective performance. ▶️ See More Gravity Flow Rack Testing Examples

Let Mallard Customize a Flow System for Your Inventory

When it comes to gravity flow racking, no two systems—or pallets—are exactly alike. That’s why Mallard offers free, in-house engineering testing to ensure your system is built to perform.

Whether you’re storing raw materials, work-in-process inventory, or finished goods, our team is here to help design a pallet flow solution that delivers maximum efficiency.

Contact Us for a quote. Schedule a gravity flow test.

 📄 Download Our Pallet Flow Brochure