Carton Flow Rack

Overview

Carton flow racks, also known as gravity flow shelving, are dynamic storage systems that use inclined roller or wheel tracks to move cartons, totes, or bins from the rear loading side to the picking face. This gravity-fed, first-in, first-out (FIFO) system³:

• maximizes warehouse space–up to 50% vs. static rack and shelving,
• boosts picking speed–get up to 40 pick locations per bay,
• minimizes errors by keeping SKUs organized and accessible.

Great for high-volume, medium-turn inventory, carton flow racks integrate with warehouse management systems (WMS) and are customizable to fit diverse SKU sizes and operational needs. They are widely used in e-commerce, retail, pharmaceutical, and food and beverage warehouses for efficient order fulfillment.

How It Works: Products are loaded onto inclined tracks (typically 1.9″ diameter polypropylene wheels or steel rollers). Gravity propels items forward, ensuring the oldest stock is always at the pick face. Dedicated SKU lanes prevent mixing, and modular designs allow easy reconfiguration.

Best Use Cases

E-commerce Fulfillment: Handles variable SKU sizes (e.g., 6″–24″ wide cartons) for rapid order picking in high-turnover environments. Example: A 12′-deep rack with 16″-wide lanes quickly and easily drops into new or existing racking, consolidating and increasing pick slots for mixed apparel and electronics orders⁴.

Image Credit: Mallard Manufacturing

Pharmaceutical Warehouses: Ensures FIFO for date-sensitive stock (e.g., 12″ x 12″ medical supply totes) with full-length lane dividers⁵ to meet regulatory requirements.

Food & Beverage Distribution: Supports perishable FIFO inventory rotation (e.g., 18″ x 24″ beverage cases at 30 lb. each) with heavy-duty rollers rated for up to 50 lb./sq. ft. Full-length lane dividers ensure SKU separation, aligning with FDA best practices for stock rotation and traceability under Code of Federal Regulations (CFR) 21⁶ Part 110 for food safety compliance.

Image Credit: Unex

Retail Backrooms: Organizes small items (e.g., 8″ x 10″ cosmetic bins) for efficient restocking and order pickup, maximizing space in compact areas.

Image Credit: Unex

Need a heavy-duty system for palletized goods?

If you’re storing full pallets and using forklifts, check out our Pallet Flow Racking Systems. They’re built for high-weight, industrial operations.

Component Breakdown

Carton flow racks consist of two primary systems: robust frameworks and dynamic roller tracks, complemented by specialized accessories.

Frames: Constructed from gauge steel, ensuring high strength for loads up to 50 lb./sq. ft. Vertical uprights and shelf frames are adjustable on ½” centers, compatible with selective or structural pallet racks for seamless integration.

Roller Tracks:

• Polypropylene Wheel Beds: Ideal for variable SKU sizes, offering smooth flow for cartons 6″–24″ wide.

• Galvanized Steel Rollers: Designed for consistent, heavier loads (up to 50 lb./sq. ft.), perfect for high-density applications like food and beverage.

Lane Guides/Dividers: Snap-on or full-length dividers maintain SKU separation, critical for high-turnover or regulated industries like pharmaceuticals.

Image Credit: Mallard Manufacturing

End Stops/Impact Trays: Heavy-duty steel trays at the load side absorb impact from heavy cartons; pick-side stops prevent roll-off, enhancing safety.

Image Credit: Mallard Manufacturing

Tilt Trays: Optional trays, adjustable up to 20°, position products in the ergonomic “golden zone” (waist to shoulder height) for easier picking.

Image Credit: Mallard Manufacturing

Mounting Brackets: Adjustable for 3–5° pitch, optimizing flow based on carton weight and size for reliable FIFO performance.

Image Credit: Mallard Manufacturing

Specialized Options could be:

• Fixed-width lanes with steel or polymer rollers, available with knuckled or straight pick faces, backed by a 7-year warranty.
• Low-profile skate wheel beds for easy retrofit into existing pallet rack beams.
• Continuous steel rollers for high-density, uniform SKU applications.

Selection Guidance

Configure your carton flow rack to match your warehouse’s operational needs:

Carton Size & Weight:

• For cartons under 12″ wide, choose 12″ wide tracks for compact storage.
• For cartons 12″–24″ wide or variable sizes, select 16″ wide wheel beds for flexibility across SKUs.
• For heavy cartons (up to 50 lb./sq. ft.), use heavy-duty steel roller tracks for durability and smooth flow.

Lane Depth:

• 3’–6′ depths suit low-volume SKUs or small bins, ideal for retail backrooms with frequent restocking.
• 8’–12′ depths support high-volume picking zones, such as e-commerce or distribution centers, requiring precise pitch adjustment for consistent flow.

Roller vs. Wheel Bed:

• Wheel beds excel for frequent SKU changes or mixed carton sizes, enabling quick reconfiguration.
• Steel roller tracks are optimal for consistent SKUs or heavier loads, ensuring reliable movement and alignment at the pick face.

Workflow & FIFO Requirements:

• For FIFO-critical operations (e.g., food, beverage, pharmaceutical), use tracks with full-length dividers to ensure SKU separation and first-in, first-out rotation.
• Adjustable pitch (3–5°) optimizes carton flow speed based on weight and material, preventing jams or damage.

Customization Options

Create your carton flow rack system to your warehouse’s unique needs:

Lane Widths: Standard 12″ or 16″ widths; custom widths available for oversized or irregular cartons.

Depths: 3′ to 12′, adjustable to match SKU turnover rates and picking volume.

Roller/Wheel Materials: Polypropylene wheels for lightweight or variable SKUs, ensuring smooth flow and flexibility. Steel rollers for heavy-duty applications (up to 50 lb./sq. ft.) or long runs, providing durability.

Accessories:

• Snap-on entry guides for easy loading.
• Full-length lane dividers to maintain SKU separation.
• Impact trays to absorb heavy carton loading.
• Tilt trays (adjustable up to 20°) for ergonomic picking in the “golden zone.”
• Knuckled shelves to enhance visibility and access.

Mobile Racks: Optional mobile flow racks with casters for flexible positioning, available in 2’–6′ widths and up to 8′ high.

Integration: Designed to drop into existing selective or structural pallet racks; compatible with conveyors for automated workflows.

Safety & Compliance

Carton flow racks are designed for safety and compliance: 

OSHA Compliance: Ergonomic design minimizes bending/reaching, with pick faces in the “golden zone” (waist to shoulder height). 

Industry Standards: Meets RMI (Rack Manufacturers Institute) standards; seismic-compliant configurations available. 

Safety Add-Ons: 

• Impact Trays: Protect tracks from heavy loading.
• Lane Dividers: Prevent SKU mixing, critical for pharma/medical compliance. 
• End Stops: Ensure cartons stay secure at the pick face. 
• Tilt Trays: Reduce strain by angling products for easier access.

Testing: Complimentary in-house testing verifies pitch and carton flow for optimal performance.

Delivery & Support

Lead Times: Engineered-to-order systems are shipped promptly based on configuration complexity, ensuring timely integration into your warehouse. 

Design Support: Free consultations to optimize pick zones and integrate with existing racks or WMS. 

Installation: Modular drop-in design for easy assembly; nationwide installation support available. 

Warranty: In some cases, up to a 7-year warranty on select components. 

Contact: Call 503-640-5666 or request a quote for a custom solution tailored to your inventory and workflow.