Carton Flow Rack
Picking operations demand efficiency. And specialized racking like carton flow rack can provide it. Built for non-palletized loads, this type of racking uses a picking and loading end with wheeled or roller lanes moving products at a slight incline down the aisle.
The result is a decrease in your team’s workload, which translates to increased efficiency.
Carton flow racks can save your team time, organize your inventory, and make the most of limited warehouse storage space.
The Basics of Carton Flow Racking
Carton flow racks, also known as gravity flow racks, are a highly productive option for many warehouses with demanding picking operations. Used for storing cartons, totes, or cases, these racks use gravity to slide products from the load end to the pick end. That puts inventory right at a picking operator’s fingertips.
Individual rack shelves are manufactured on an angle and fitted with rollers or wheels. You can customize these rollers to specific application needs in terms of size, speed, and shape.
Lower Labor Costs
Carton flow racking allows for easy access to products and reduces the time employees spend traveling around the warehouse to retrieve items. In other words, they minimize picking and restocking hours.
Space-Saving
Carton flow racks maximize vertical and horizontal space That allows for more efficient storage of smaller items and enables higher storage density.
Improved Ergonomics
Carton flow racks are ergonomically designed to automatically move items to the front of the rack as items are removed. This design reduces the need for employees to reach or bend excessively. This helps prevent strain and repetitive use injuries and improves worker safety.
Why Invest in Carton Flow Racks?
As your warehouse evolves, so do your picking needs. Carton flow racks can eliminate unnecessary walking (and time!) for pickers. Instead of moving across the facility to reach an item, they walk a few steps to organized lanes to gather the products on their picking list. This difference alone saves companies up to 50% in labor.
Carton flow racks are also the preferred choice for product consolidation. Static racking frequently requires that products be spread out over a larger area in the warehouse. That can mean more storage space and less efficient picking.
The opposite is true for carton flow racking. Once pallet loads are broken down, these racks consolidate products, freeing up space for more storage. This is particularly helpful for warehouses at or nearing capacity or for products that move quickly.
Carton flow racks can function as an independent piece of material handling equipment or part of a larger storage and picking system. This flexibility allows smaller operations to benefit from the picking efficiency these racks offer. Larger, fast-paced distribution centers also benefit when combining the racks into sophisticated pick modules, which combine multiple types of equipment, including racking and conveyors.
These racks use a first-in, first-out (FIFO) inventory management system. Products enter the rack on one side and roll down the racks on rollers, where pickers can then remove to fill orders on the other. FIFO ensures the oldest products are first in the picking sequence — a very helpful process for time-sensitive products like those with expiration dates.
Carton Flow Rack Operation
Will carton flow racks work for your warehouse operations? And more importantly, how can you use carton flow racking to maximize efficiency?
Here are a few questions to ask yourself:
- What types of products will fill the rack?
- What is the product and container weight?
- How often do you need to reslot?
- What is the surface area of the carton or tote?
- Are all the products uniform in size and weight?
- Do you pick full cases, individual items, or a mixture?
Usage doesn’t require all pieces to have a uniform dimension or weight. However, this information is helpful in warehouse planning and design to ensure the carton flow rack meets your specifications. Knowing the surface area of the totes or containers helps determine the spacing for the gravity rollers on individual shelves.
Planning is integral to all aspects of your warehouse, including any expansion plans for racking. Adding to carton flow racks is seldom an issue. Just make sure any new racking is compatible with the existing structure.
What’s the Difference Between Full Case and Split Case Picking?
Full case picking involves selecting entire cases of products, making it ideal for bulk orders. Split case picking focuses on picking individual items from open cases, which is better suited for operations with high product variety and smaller order sizes.
Both types of picking work well for carton flow racking. Full case picking typically involves larger lanes to accommodate full cases, while split case picking often involves smaller lanes to accommodate open cartons.
Understanding your picking needs is the first step in designing an effective picking system using carton flow racking.
Ready to Make the Most Out of Your Picking Operations?
Carton flow racking is a great way to add some extra productive power to your warehouse floor. These racks are the perfect choice for picking cartons, totes, and cases quickly and efficiently. Browse our selection of carton flow racks to find the right equipment for your business.
Setting Flow Angles
Setting the right flow angle for carton flow racking is essential for proper operation. The weight and quality of the items being moved should determine the angle, or pitch.
For example, totes or lightweight cartons (1 to 10 pounds) may only need a pitch of 3/4″ to 7/8″ per foot. Meanwhile, heavier cartons (30 to 60 pounds) could require 1″ or more. This will ensure that products can move through the system without issue.
Your Go-To Carton Flow Rack Supplier
Are you looking to add speed and efficiency to your warehouse picking operations? Carton flow racks might be exactly what you’re looking for.
At East Coast Storage Equipment, we carry a wide selection of used carton flow racks and can assist with the design and installation process. Our experts are on standby to help you with every step. Get in touch online or call 888.294.5022 to learn more about your equipment options.