Pallet flow rack, also known as gravity flow pallet rack, is a dynamic storage system that offers high-density storage (2 to 20 pallets per lane) as well as a first-in first-out retrieval order. This system fully utilizes the available storage space while ensuring faces along the picking aisle remain regularly stocked. The pallets can be loaded at the top end of a slightly inclined rack and glide safely and effortlessly along rollers at a controlled pace to the other side.

Personalization is the key to effective pallet flow racking system and manufacturers offer various kinds of rollers designed and engineered to cater to diverse applications. Some manufacturers can also tailor these racks with speed controller abilities that are exclusively designed for users’ product weight ranges. First Access has years of experience designing pallet flow racking systems and can help you create a flawless system to surpass your expectation and enhance your storage efficiency.

How Pallet Flow Rack Works

Pallet flow racking systems are usually FIFO (first in, first out) and the pallets are loaded into the storage lane from the loading aisle and fed through gravity flow towards the discharge aisle. Initially, the pallets are put on the rollers that allow them to flow in the direction of the front of the racking system. After they have glided to the front of the racking system, the pallets rest on pallet stops until they are unloaded from the pick face.

As pallets are unloaded or removed from the racking system, every pallet that was at its rear rolls ahead one position. This process can take place until the lane gets empty or for an indefinite period if more pallets are loaded into the racking system. The speed of the pallet is managed by the kind of brakes and rollers engineered into the system.

Types of Pallet Flow Tracks

• Skate Wheel Rollers – These are usually utilized with standard wood pallets in pallet flow systems that have short lanes. They are normally the most cost-effective option for pallet flow roller.
• Magnum (Poly) Wheel Rollers – These are the most heavy-duty kind of pallet flow roller available. They are perfect for loads reaching over 3,000 pounds and are wonderful for freezer storage applications.
• Full-Width Rollers – These are perfect for applications with multiple pallet sizes for products due to their width of support. Full Width Bed Rollers are the most flexible pallet flow roller option available on the market, but also the most costly.

Pallet Flow Rack Safety

• Maintenance – In order to keep the warehouse safe and averting the pallet from losing its stability and strength, appropriate maintenance is the key. It is recommended to carry out safety checks on a regular basis that will help to keep an eye on the structural integrity of the system and ensure the proper functioning of its components. Especially, roller tracks or wheel beds must be comprehensively scrutinized to make sure pallets will appropriately flow and stay on the track while gliding through the system.
• Safe Loading – In this system, pallets are loaded on one side of the system and move by means of roller track to the other end where they are unloaded. Correct placement of pallets on the loading end of the system is essential. The forklift operators must place pallets straight and perfectly to ensure a proper flow.
• Safe Unloading – After pallets have been carried by means of gravity to the unloading end of the system, they will rest there until unloaded. The pallet being unloaded is the sole obstacle between the subsequent pallet in the line and the front of the system. For a smooth transaction, the forklift operators must unload the pallets slowly.

Advantages of Pallet Flow Rack

• Turns a static warehouse into a dynamic, “flowing” warehouse
• Requires the little maintenance
• Can be custom engineered and tested for your specific application
• Perfect for cooler or freezer applications
• Promotes high-density pallet storage
• Forklift operator friendly, efficient, and practical
• Can be retrofitted into standard existing racking
• Promotes steady product rotation with a FIFO model
• Time-saving (just a single input and a single output aisle)
• Offers increased order picking efficiency and improved productivity

Applications of Pallet Flow Rack

• Food distribution and freezers where maximum storage volume or cube is required
• Perfect for time-sensitive large volume and consumer goods
• Fast-moving products with FIFO stock rotation requirements
• Any place where the rotation of perishable products is important

Considerations for Pallet Flow Rack

• Product loads have to be stable and firmly secured to pallets
• Pallets have to be in good condition and not have broken or missing bottom boards
• The overhang of loads has to be considered seriously in the design process

Frequently Asked Pallet Flow Rack Questions

How Many Pallets Deep Can Pallet Flow Racking Accomodate?

The majority of pallet flow rack systems can hold anywhere from 2 to 20 pallets in every lane and can go up as high as your lift equipment can reach.

What’s the Usual Pitch of a Pallet Rack Flow Lane?

It actually differs from system to system. That being said, ½” per linear foot is the most common pitch given to pallet flow lanes. To exemplify this, visualize a pallet flow lane that is 20’ long. If the pitch is ½” per linear foot, the loading end of the lane will be 10” higher than picking end. This slant lets the pallet to “flow” smoothly from one end of the system to another.

What’s the Projected Lead Time for a Pallet Flow Project?

Lead times usually range from eight to twelve weeks since pallet flow racking systems are constructed on a per-project basis. Sometimes there are used options available immediately, but it is critical to make sure they are right for the specific customer application.

With a promising pallet flow system, you can increase throughput and efficiency in the warehouse setting while maximizing you storage cube. Let First Access design your pallet flow system today.