A Simple Trick to Restart Pallets in Pallet Flow

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Pallet hang-ups are a common yet easily avoidable problem for some pallet flow rack users. It happens when a rear pallet, typically deeper in the lane, either stops or won’t restart when the front pallet is extracted. Most hang-ups are caused by everyday warehouse conditions like weak/broken pallets, pallet loads that settle on tracks, temperature changes, etc.  Luckily we have an easy fix. In the field, we call it “Plugging” the pallet flow lane.  Plugging relies on simple physics, or inertia, to get those stubborn hung-up pallets moving again.

How to Fix a Pallet Flow Hang-Up - Mallard ManufacturingThe Plugging Method for Pallet Flow:

  1. Lift the front pallet 1″ above the wheels or rollers
  2. Firmly push or bump the rear pallets back into the lane, about 4″
  3. Slowly back out, extracting the front pallet and gently “plugging” the rear pallets forward

Simple, right? Plugging may not be necessary for every system or situation, but we highly recommend using the approach for ALL pallet extractions to avoid unnecessary, time-consuming hang-ups.

You can use this technique with all styles of flow rack, including full and split-roller and Magnum wheel systems. Contact the Mallard gravity flow rack experts for more information.