Pick Modules

What Is a Pick Module?

A Pick Module is a rack-supported picking system built around your warehouse. Unlike standard pallet racks, every level in a Pick Module can be used for picking or reserve storage. Forklifts reload pallets in separate aisles while pickers work safely in their zones.

Key Components of a Pick Module

The storage you choose—pallet flow, carton flow, pushback, or selective rack—determines how product moves through the system and how orders get filled.

Rack-Supported Pick Modules use pallet racking as the backbone, often running one to four levels high. Cross-aisle beams hold up the flooring and platforms above, with bar grates for light and sprinkler access or solid decks like plywood/resin for easier walking and cart use. Stairs, rails, and pallet gates tie into the rack structure for safe, ergonomic access. Forklifts replenish through load aisles or pallet gates, while pickers work undisturbed in the pick aisles.

Key components of Pick Modules can include:

• Pallet flow rack for feeding full pallets to case-pick zones or holding reserve inventory
• Carton flow rack for medium- to slow-moving SKUs, perfect for case or each picking
• Industrial shelving and bin storage work well for slower movers or odd-shaped parts
• Mezzanine levels to use vertical space, with stairs, guardrails, and decking for safety
• Conveyors—powered, gravity, or spiral—for moving picked items to sortation or packing

This setup keeps forklifts in loading zones and pickers in picking zones for faster, safer operations.

How a Pick Module Works

Every Pick Module layout is custom, built around your warehouse needs. Most follow proven workflows that combine rack-supported platforms with flow storage systems. Here’s how we apply them to solve real operational challenges.

1. Multi-Level Zone Picking

Many 3PLs or e‑commerce warehouses use the first level as their main pick zone to save floor space—but that leaves upper levels underused. Pick Modules let you pick from any level safely, creating multiple active pick zones while forklifts replenish stock overhead.

However, if load limits, deck construction, or aisle widths aren’t planned correctly, pickers take longer routes, forklifts get blocked, or safety violations happen. Speedrack West engineers plan for all of that. We calculate loads, plan safe aisles, meet safety regulations, and design for future growth. The result is a layout where pickers move fast, forklifts run freely, and you avoid costly mistakes. Thinking of adding or expanding pick zones? Fill out the form—we’ll design a layout that works now and grows with you.

2. Replenishment vs. Pick Face

High-volume fulfillment often means running replenishment and picking at the same time. During peak season, your team may need to constantly restock pallets while pickers assemble orders with multiple SKUs. Without the right system, workers end up waiting for forklifts or navigating blocked aisles.

Pick Modules handle this using pallet flow lanes, carton flow, or gravity-fed systems. Forklifts load stock in the back while pickers pull from the front, keeping orders moving without interruptions.

But this takes precise design. Incorrect aisle spacing or poorly planned pick zones can create bottlenecks and safety hazards. Speedrack West ensures racks, flow lanes, and mezzanines are all aligned so replenishment and picking happen simultaneously—safely and efficiently. Your crew can build orders, break down pallets, and pack boxes without slowing down.

3. Integration with Conveyors and Carton Flow

For manufacturing or cross-docking operations, moving inventory between production, storage, and shipping zones can consume a lot of time. Pick Modules with integrated conveyors solve this.

We design conveyor layouts to move product straight from production to the pick face, or from storage to the dock. Proper planning is critical—if conveyors block forklifts or force pickers into long detours, throughput drops.

We select the right type of conveyor—gravity, powered, spiral, or pallet/box-specific—and design layouts that fit your facility. The result: continuous workflow, reduced handling time, and safer operations. Whether your facility is a manufacturing warehouse, high-volume e-commerce hub, or cross-docking center, we make sure your pickers get what they need fast and safely.

What Problem Does a Pick Module Solve?

Pick Modules are used all the time in high-volume distribution centers, e-commerce hubs chasing same-day orders, 3PLs dealing with mixed SKUs, and manufacturers handling seasonal peaks. Why? Because they fix the everyday problems that slow crews down:

• Wasted travel time between pick locations
• Reserve pallets taking up space instead of staying overhead
• Dead-end aisles and scattered pick zones
• The need for more throughput without adding floor space
  

So if you’re dealing with challenges like below, it’s time to take a hard look at Pick Modules:

• Thousands of SKUs crammed in a tight space
• E-comm or retail orders spiking 500+ lines per shift
• Case or split-case picking across multiple zones
• Crews running waves or batches, needing quick paths
• Travel time eats up 30% of your pick rate
• You are 3PLs or manufacturers dealing with seasonal peaks

Custom Pick Module Design with Speedrack West

We don’t sell stock racks. Every Pick Module is designed to fit your facility. Here’s how we work with you:

1. Layout Planning: We review your floor plan, SKU mix, and pick volume.
2. CAD Design: Engineers map every level, aisle, and pick zone.
3. Permits & Compliance: We handle OSHA/RMI and local codes.
4. Integration: Tie into conveyors, carton flow, or your WMS.
5. Installation & Service: We install nationwide and stay on-site to guide your crew.

Request a Pick Module Design today. Let’s sketch your setup and show you the costs.