What Is Pallet Flow Rack & How Does It Work? | Mallard Best Practices
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Pallet Flow Rack 101
If you’re new to gravity flow solutions, you may hear the term “pallet flow rack” and wonder what it is and how it can be applied to address your warehousing challenges. Well, you’ve come to the right source. At Mallard Manufacturing, we are the Home of Gravity Flow, and our pallet flow rack systems are adaptable and customizable to satisfy a range of warehousing applications.
From maximizing your storage space to reducing labor costs and improving productivity, pallet flow rack can be a game-changer for your operation. And, even if you’re already familiar with pallet flow racking, you may be surprised by the full range of applications it can handle and the efficiency it can unlock for your warehouse. Let’s take a look!
Back to Basics – What Is Pallet Flow Rack?
Split-Roller Pallet Flow Rack System
Pallet flow rack is a dynamic storage system designed to store and retrieve palletized inventory efficiently. Unlike static racking systems, pallet flow racks use sloped lanes equipped with rollers or wheels to allow pallets to glide from the loading (or input) side to the picking (or output) side using the force of gravity. Each pallet flow lane is designated to a single SKU, and lane depths can range from 2 to 20+ pallets deep, making them ideal for high-density storage and high-volume SKUs.
Pallet flow rack systems are typically configured for First-In/First-Out (FIFO) inventory rotation, making them especially useful for industries that handle perishable goods, such as food and beverage, pharmaceuticals, and cold storage. However, they can also be adapted for Last-In/First-Out (LIFO) configurations by consolidating into a single aisle for loading and picking functions. This “push-back style” design often accommodates other storage needs for manufacturing and distribution centers.
How Does Pallet Flow Rack Work?
The functionality of pallet flow rack is straightforward yet highly effective. Here’s how it works:
- Loading the Rack: Pallets are loaded onto the lanes from the loading side of the rack. The lane pitch and rollers help activate the gravitational flow of the pallet.
- Controlled Flow: The design ensures pallets flow independently within a safe velocity. For this reason, every pallet flow solution is customized to your pallet and inventory specs. Depending on the length of the flow lane and pallet load weight, speed controllers may be necessary to ensure a smooth and controlled descent.
- Picking the Pallet: When the pallet reaches the end of the lane, it rests in the pick position, ready for retrieval by a forklift or other material handling equipment.
- Automatic Replenishment: Once a pallet is extracted, the next pallet in line automatically flows into the pick position, ensuring a continuous supply of inventory.
Benefits of Pallet Flow Rack
Pallet flow rack offers numerous benefits that can help optimize your warehouse operations:
- Space Maximization: By utilizing deep lanes and vertical space, pallet flow rack significantly increases storage density compared to traditional selective racking systems. This makes it an excellent choice for warehouses looking to store more inventory without expanding their footprint.
- Improved Productivity: With inventory at the pick face, workers are not delayed waiting on restocking, boosting overall productivity and reducing bottlenecks in high-demand workflows.
- Low Per-Pallet Cost: Compared to other high-density storage options, pallet flow racks offer a cost-effective solution by maximizing storage capacity and minimizing operational expenses.
- Customizable Design: Pallet flow rack systems are tailored to accommodate different pallet sizes, weights, and operational requirements.
Floor-Mounted Pallet Flow: Did You Know Pallet Flow Also Does This?
Ergo Build High-Volume Mixed-SKU Pallet Building
Floor-mounted Rails & Empty Pallet Return Lanes (Yellow)
Pallet flow wheeled and roller tracks aren’t just for traditional high-density storage –innovative uses can enhance operational efficiency. Here are three key uses for floor-mounted pallet flow:
1. High-Throughput Case Picking: Floor-mounted pallet flow lanes can feed palletized inventory directly to a picker for hand-picking individual cases. This setup is often paired with takeaway conveyors as part of a pick module or pick tunnel to streamline operations and reduce manual labor.
We also recommend empty pallet return lanes within the pick area to swiftly and safely remove empties. With four design options, you can tailor your solution to optimize your pick area.
2. Mixed-SKU Pallet Building: For operations that require building mixed-SKU pallets, pallet flow lanes can feed inventory into the pick aisle for seamless layer picking. Reverse flow lanes interspersed within the row support mixed-SKU pallet building within the layer pick aisle. For high-volume operations, Mallard’s semi-automated Ergo Build solution takes efficiency up another notch.
Full-Roller Pallet Flow Staging
3. Dock Staging and Inventory Intake: Floor-mounted pallet flow lanes are ideal for dock staging and inventory intake. They help minimize the need for forklifts and operators while also reducing dock traffic, improving overall safety, and streamlining the movement of goods into and out of the warehouse.
Applications of Pallet Flow Rack
Pallet flow rack systems are versatile and applicable across a variety of industries and operations. Whether ambient, refrigerated, or freezer storage, we have the products to best meet your needs. Here are some common applications:
- Food and Beverage: Efficient storage and rotation of perishable goods in temperature-controlled environments.
- Manufacturing: Staging raw materials and finished goods to streamline production workflows –from food and pharma manufacturing to automotive parts and heavy equipment.
- Retail Distribution: High-density storage for fast-moving consumer goods.
- E-Commerce Fulfillment: Quick access to inventory to support rapid order fulfillment.
- Cold Storage: Space-efficient storage for refrigerated and frozen goods.
Why Choose Mallard for Your Pallet Flow Rack Needs?
At Mallard Manufacturing, we don’t just supply pallet flow rack systems—we engineer solutions tailored to your specific operational needs. With decades of expertise and a relentless commitment to quality, we deliver gravity flow systems that are durable, reliable, and performance-driven… And we don’t stop there! The Mallard Innovation Lab is an interactive test center where we simulate your gravity flow solution with your pallets and sample inventory to ensure it flows as intended once installed.
Whether you’re looking to optimize a single operational application or overhaul your entire warehouse, our team is here to help.
Contact Mallard Manufacturing today –Discover why we’re the trusted name in gravity flow solutions, and let us help you achieve your operational goals.
Visit our Team at Promat –Booth #S2368
