High-Density Pallet Flow Racking System for Semi-automatic Storage

Pallet flow rack system is a dynamic high-density storage system working on first-in-first-out(FIFO) retrieval orders. It achieves dense storage by reducing aisles while at the same time allowing for quick and efficient inventory turnover. Thus, it is best suited for warehouses with high volumes of perishable or time-sensitive goods.

To improve material handling efficiency, pallet flow racks are equipped with gravity roller tracks on which pallet cargoes are loaded. The tracks are set with a slightly tilted pitch so that pallets are able to move by gravity on these slopping roller lanes from the high end to the low end. Usually, the high end will be the rear side for loading pallets and the low end will be the front side serving as the picking face.

When it is time to load cargoes, forklift operators place pallets at the rear side, then pallets roll forward under the function of gravity to the pick face. Once a pallet is removed from the front side, the next pallet will roll into place for picking up. Besides, there are brakes installed within roller tracks controlling the speed of pallet movement so as to guarantee safe handling.

Advantages of Pallet Flow Rack System:

• FIFO Inventory Rotation Order: It follows the “FIFO” retrieval order. The first stored pallet will be the first one to take out, which is necessary for perishables or goods with expiration dates so that the oldest items can be picked up first to prevent waste and spoilage.

• High-density Storage: Rows of racks are adjacently aligned and aisles are positioned at the front and rear side of the system, greatly reducing the space occupied by working aisles and leaving more space for storage.

• Efficient Storing and Retrieving: By using roller tracks, it achieves semi-automatic storing and retrieving. Forklifts only need to work at the in feed side and pick-up side, besides, loading and unloading can carry on at the same time, which cut down handling time and improve working efficiency.

• Good Selectivity: Every lane can store a different SKU and every SKU can get immediate access.

• Less damage: Forklifts do not have to travel among racks so there is less opportunity for damage.

• Decreased Equipment Costs: The system is accessible by most types of forklift trucks and fewer forklifts are needed for reduced aisles.​

Tips for Pallet Flow Rack System:

• Pallet flow rack system is suitable for frozen storage warehouses, food distribution and high volumes of customer goods which are time-sensitive and need to be removed quickly.

• Per pallet position in pallet flow racks costs more than that in other high-density racks like drive-in pallet rack and push-back pallet rack. Pay attention to your budget if you choose pallet flow racks.

• When loading pallets, be careful to properly place pallets on the loading end of the rack system and do not to collide with the racking. When unloading pallet, the forklift operator should lift up the pallet being unloaded slowly to guarantee the safety of the next pallet in line.

• It’s advisable to perform routine safety checks on pallet flow rack system in order to monitor the system’s structural integrity and verify the proper function of its parts. Specifically, wheel beds or roller tracks should be thoroughly inspected to ensure pallets will properly flow and remain on the track when moving through the system.

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Founded in 2004, Ironstone-Meca Industry is a professional storage equipment manufacturer providing full ranges of services including design, consultation, production, technical guidance,  installation and maintenance support.  

The mission of Ironstone-Meca Industry is to be an innovation driven, customer oriented company with excellent products, perfect storage solutions, all round customer services and full commitment of on-going improvement in the Logistics industry today and the future. 

Completed countless successful projects received numerous praises, Ironstone has always treated rack safety and quality as the foremost factor. Having our products certified in US and Australia market with RMI standard testing and AS4084-2012 standard, Ironstone has developed some big agents in the glabal market and will develop more under the support of our loyal customers. 

Helping our customers to find the perfect warehouse managment solutions, Ironstone can maximize your profits with lowest cost. You will get warm welcome from us if you visit our factory in China!