The Large Role for Gravity Flow Within Micro Fulfillment

Pick Reserve

The evolution of point, click, purchase has seemingly changed the distribution and fulfillment landscape with shocking speed. As so many end users pivot to online ordering, distributors are pivoting to micro fulfillment centers (MFCs) as a means of meeting demand. Micro fulfillment sites are smaller order processing facilities located closer to concentrated bases of customers. These small, nimble facilities quickly fill e-commerce orders often with the help of automation solutions to speed pick rate and ensure accurate inventory selection.

Micro Fulfillment Center Characteristics

• Average 5,000 – 20,000 square feet
• Often located in urban areas
• Usually within 40 miles of customer base
• Stores 5000 – 15,000 SKUs
• Small item focus – eaches & carton picking

The level of automation deployed in the micro fulfillment center will likely hinge on the breadth of SKU lines. The more SKU lines, typically the more hand picking is needed.

However, coupling automation with gravity flow is a win-win solution for organization, processing speed and accuracy. Here are a few ways to boost productivity with this heavy-weight combo.

Carton Flow Rack

Pick Aisle

Carton flow racking is ideal for case and each picking in any size warehouse but particularly where space is very tight. The gravity flow fed lanes keep product orderly for accurate picking and provide a constantly replenished pick face. Separate load and pick aisles reduce congestion in the pick aisle. Wheeled carton flow offers full edge to edge use of the rack bay to maximize SKU storage and can fit inventory of varying sizes. Roller carton flow is often the best option for consistently sized inventory like cases and totes.

Carton flow rack can be equipped with tilt trays to better position inventory and promote ergonomic posture for the worker. Tilt trays also help improve pick accuracy.

Gravity Conveyor Rack

Gravity conveyor rack can be installed in the pick aisle to minimize worker travel and speed up processing from picking to packing. Roller conveyor rack is a simple to operate and install, cost-effective warehouse tool.

Mobile Carton Flow Work Cells

Carton flow work cells are mobile, ergonomic workstations that support FIFO inventory rotation of small items, cartons, and parts. They are ideal for seasonal order picking applications, kitting, light assembly, and small-parts packaging. Shelves are easy to move and adjust vertically for SKU changes and the work cell can be equipped with wheeled or roller tracks depending on inventory specs. Mobile carts move easily by hand or they can be pulled by forklift with the optional tow assembly device.

Pallet Flow Rack

Pallet flow rack can be valuable tool in a multitude of ways particularly when space is at a premium.

Floor-mounted pallet flow can be installed for push-assisted inventory intake or within a load aisle for breaking down palletized content to load carton flow rack.

For high-throughput case picking, workers can pick directly from floor-mounted pallet flow. Several benefits of this design include deep-lane reserve storage to ensure workers have a consistently replenished supply of pallets and separate load and pick areas to eliminate bottlenecks.

Pallet flow can also be mounted within pallet rack to store full reserve pallets in a FIFO inventory rotation. Pallet flow rack can be used even with automated guided vehicles (AGVs) with the addition of a simple scraper plate feature. The Mallard team can supply these accessories if needed.

Empty Pallet Return Lanes

Removing empty pallets from the case pick and/or carton flow load areas is a necessity. EPR lanes handles this task with simplicity, safety, and efficiency. Pallets are protected from damage to be able to be returned or reused and work areas are kept orderly and safe.

Floor-Mounted Pallet Flow with EPR Lane

Power Up with Gravity Flow Solutions

We like to remind our customers that gravity is a powerful force. Harnessing gravity to work for you is what we do best. Call the Mallard team to discuss your warehouse challenges, micro fulfillment center aspirations, and current or future processing goals. Our gravity flow rack experts are here to help apply the best, make-sense solutions to meet your needs.