Smooth Pallet Flow Rack for Non-Standard Crate Stacks: See Our Latest Forklift Separator Test
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Optimizing Deep-Lane Pallet Flow Rack For An Advanced Automation Systems Provider
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Tall, narrow, and heavy — non-standard pallet loads present a unique challenge for warehouse storage systems. Their unusual specs demand a customized approach to pallet flow rack design—and that’s precisely what we deliver. In a recent in-house test, we engineered a full-to-split roller lane, complete with FIBA speed controllers and the FL301 Forklift Separator, to safely manage crate stacks in a high-efficiency operation. Here’s how the system performed—and why this design works when standard solutions fall short. The customer’s unique pallet specs included:
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The Custom Pallet Flow Rack Design
To meet the demands of these tall, heavy, and narrow crate stacks, our engineers designed a pallet flow rack solution tailored to maximize contact, minimize risk, and ensure performance.
Full Roller Transition to Split-Roller Lane
- 1.9″ diameter rollers placed on 2” centers
- Full-roller section ensures maximum contact with crate runners
- Split-roller design near the discharge end allows seamless integration with the FL301 Forklift Separator
- 7/16” per foot pitch
Skate Wheel Lane Guides
- Side-mounted skate wheel rails keep pallets square in the lane
- Prevents skewing and ensures centered pallet engagement with the separator
- Simplifies and speeds up forklift pick at the discharge zone
FIBA Speed Controllers
- Installed every 48 inches along the flow lane
- Combine ultra-grip roller contact with undermounted resistance for dual-action speed control
- Designed specifically for full roller applications
Forklift Separator: Critical for Deep-Lane Flow Safety
Rear Pallets Holding as Front Pallet is Removed
The FL301 Forklift Separator is custom-built for deep-lane pallet flow racking systems. It’s especially valuable when handling heavy loads at higher elevations.
Key Functions of the FL301:
- Holds rear pallets until the front pallet is lifted
- Creates a flue space buffer to prevent contact with rear pallets
- Resets automatically for seamless lane indexing
- Prevents back pressure from damaging inventory or forklifts
🔍 Back Pressure Formula:
.06 x load weight x number of rear pallets
For this 5-deep system, the calculation is: .06 x 2400 x 4 = 576 lbs. of added force on the front pallet
That’s a lot of pressure completely eliminated with the forklift separator.
Real-World Testing: The Proof Is in the Flow
The Mallard Engineering Testing Lab ran 15 customer-supplied pallet loads through the custom lane to validate the design. Each wooden crate was built to the same spec: 44” wide x 28” deep x 28” tall.
Here’s what we observed:
✅ Smooth flow throughout the full and split-roller sections
✅ Zero hang-ups during indexing and unloading
✅ Centered pallet alignment thanks to skatewheel guides
✅ Effective speed control with no excessive acceleration
✅ Reliable separator function, creating the needed flue space at discharge
The team instructed the customer that, in the event of a hang-up, simply loading an additional pallet into the lane would gently prompt forward-positioned pallets to flow.
Why Custom Pallet Flow Rack Design Matters
This system wasn’t off-the-shelf—and that’s the point.
When your inventory or equipment doesn’t follow standard specs, a custom pallet flow rack can protect your people, your product, and your process. In this case, Mallard’s solution delivered on all fronts.
This project also highlights the power of our in-house test lab—a proving ground where your system is challenged, observed, and refined before it ever reaches your warehouse floor.
Contact the gravity flow experts to discuss your inventory and storage challenges. Let’s harness the power of gravity to benefit your team and operation.
