Pallet flow racking is a high-density storage system where pallets are stored on rollers or roller conveyor systems. The pallets are loaded onto the rollers at the rear of the system and conveyed by gravity to the front of the system for easy unloading. The system is designed to have a decline slope from back to front and a braking system to control the speed of the load’s decent.
These systems are typically designed from 2 to 15 pallets deep but can be constructed much deeper if warranted. Forklift aisles run perpendicular to the front and rear of the system to assist in the loading and unloading processes.
Pallet Flow Racking is best suited for moderate mix, high volume SKUs
How does Pallet flow Racking Compare to Other Options?
- Selectivity: Unlike drive-in racking, each level of the system provides storage for a different SKU and therefore has more pick faces and greater selectivity. SKUs within each level should be consistent.
- Inventory Rotation: The system is designed to provide FIFO inventory rotation.
- Density: This is a high-density storage system and can be designed with very deep lanes. However, the incline required for the conveyor may result in fewer levels compared to drive-in racking depending on the ceiling height and the depth of the system.
- Damages: Forklifts do not have to enter the rack so there is less opportunity for damages.
- Investment: Pallet flow racking is more expensive then drive-in or push back racking, per pallet position.
- Honeycombing:Pallet flow systems have less honeycombing than a drive-in or pushback system. Each lane should contain only one SKU, however stock rotation is not a concern.
- Flexibility: The systems are designed and engineered for particular load dimensions and weights. Reconfiguration is possible but can be time consuming and expensive.
- Pallet quality and consistency is important to ensure the loads convey properly and do not get hung-up due to broken boards or debris.
Layout and Equipment Considerations
- Material Handling Equipment: Standard forklifts and reach trucks can be used. With heavy loads or deep configurations the equipment can sustain additional wear and tear.
Do you need components or design help with a pallet flow pallet racking system?
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