The Risks of Buying Used Pallet Flow Rack Systems | Mallard Buyer Beware
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What Facility Managers Need to Know Before Installing Used Pallet Flow Rack
Used pallet flow rack systems may appear to offer an attractive cost advantage, especially for operations looking to optimize storage on a budget. But when that decision skips critical steps like system validation, safety inspections, and performance testing, the results can compromise more than just productivity—they can put your team and your inventory at risk.
Recently, the Mallard team was asked to assess a used pallet flow system installed in a large distribution facility. It’s not the first time we’ve been called in to evaluate a used system that couldn’t meet the demands of its intended application. By sharing these experiences, we aim to help warehouse managers avoid committing to equipment before it’s been properly assessed by a gravity flow expert.
What We Found: A System in Compromised Condition
Assessing Used Pallet Flow Rack
Our team conducted a full on-site review of the pallet flow rack system. The equipment, installed without pre-installation testing or engineering validation, consisted of approximately 630 lanes outfitted with three staggered rails of 2.9″ diameter wheels and drop-in speed controllers.
System Summary:
- Lane Length: 32′
- Installed Pitch: approx. 0.54 inch per foot
- Rail Types: Steel skate wheels at charge zones, plastic wheels in field sections
- Frames: 3.5″ tall
- Speed Controllers: Drop-in style
- Rail Spacing: Approx. 36″ (out-to-out)
- Test Pallet: 40″ x 48″, 4-stringer with 8 bottom boards
Despite the significant investment in equipment and installation, our findings were conclusive:
Evaluation Summary: The system was found to be in a severely compromised condition, with multiple structural, mechanical, and operational deficiencies. Based on observed conditions, it is not functionally reliable or operationally safe.
The Hidden Costs of Buying Used Pallet Flow Rack
In conversations with facility management and their consultants, multiple red flags came to light:
- Inconsistent flow times ranging from 27–51 seconds per lane—a wide variation that causes unpredictability on the pick face.
- Suspected sheared bolts—bolts were found loose or broken within the system, suggesting unsafe force during flow.
- Concerns over used speed controllers—older or improperly matched controllers may contribute to erratic flow behavior or complete failure.
These issues weren’t just mechanical—they represented serious safety concerns for personnel working within and around the flow system.
Why Testing & Engineering Matter More Than Price
Mallard Interactive Testing Lab in Action
At Mallard, we understand the pressure to control operational costs—but we also know that gravity flow systems, whether pallet flow or carton flow, must be carefully specified to perform reliably and safely. Every system is engineered around the specific pallet or carton dimensions and weight, the style and condition of the inventory, application needs, and available space.
In pallet flow systems, especially when managing significant load weights and dynamic movement within the rack, these factors are crucial to safety and performance. That’s why we do not recommend installing used pallet flow systems. There is no substitute for a professionally engineered, tested, and validated solution tailored to your unique operation.
Our Proven Process Includes:
- Engineering validation based on your pallet type, inventory load weight and distribution, and warehouse layout
- System testing in our in-house, interactive lab to confirm ideal pitch and lane configuration
- Quality components—rails, wheels/rollers, speed controllers, guides, separators, and more
- Professional installation instructions and support to ensure safe, reliable operation
When working with a used pallet flow rack system, even experienced installers may not have access to the original engineering specifications or installation instructions tailored to that specific equipment and inventory load.
Without that vital information, it’s difficult—if not impossible—to ensure that the system will function safely and efficiently in a new setting. Inconsistent performance, excessive wear, and safety concerns often follow, leading to costly downtime and operational headaches.
5 Lessons from the Field: Used System Watch List
If you’re evaluating a used pallet flow rack system—or already using one—ask these critical questions:
- Was the system previously tested with my pallet type and inventory weight?
- Are all speed controllers and wheels functioning as intended?
- Has the rack been inspected for structural wear or damage?
- Was the installation completed by experienced rack professionals?
- Does the system deliver consistent flow performance across lanes?
If the answer to any of these is no or unsure, it’s time to call in a trusted expert.
Don’t Settle for Uncertainty—Let’s Talk Solutions
Deep Lane Pallet Flow Rack System
Need help evaluating or replacing your pallet flow system? Contact Mallard Manufacturing today to speak with a gravity flow expert.
You can also explore our full Pallet Flow Rack solutions to learn more about engineered options and design tools to support your warehouse goals.
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