Pallet Flow Rack Explainer

What is Pallet Flow Rack?

Pallet flow rack is selective rack placed back-to-back to allow for more storage space. Inclined conveyor wheel sections are installed in the rack, enabling back-loaded pallets to flow via gravity to the front or pick face.

Pallet FlowPallet flow rack consists of:

  • Pallet Rack
  • Gravity Flow Rails
  • Gravity Flow Speed Controllers

How it works:

Flow rails slant towards the unloading side of the pallet rack, using gravity to move pallets from the loading side to the picking side for retrieval.  Flow speed controllers are used to control the speed of the pallet as it moves along the rails. Once one load is removed from the unloading side of the pallet flow racks, the next slides into it’s place.

Why Pallet Flow Rack?

Pallet flow rack is not only designed to save valuable floor space and cut down on labor, but it provides high-density storage with multiple order picking levels.  This system is what we like to call a First-In, First-Out flow system (FIFO), which ensures that the faces along the picking aisle are always stocked.

Does this sound like something you are interested in knowing more about?  Is it the perfect fit for your warehouse operation?  Give us a call at 866.474.2001 and one of our knowledgeable sales representatives will be able to help you get what you need!

We also do customizable warehouse configurations, so if a reconfiguration is in order, definitely be sure to contact us!

We recently completed a project for a new regional parts distribution center for heavy-duty mining equipment in the Southwest United States.

For this project, we had to configure a system that could accommodate various part sizes, ranging from small hardware (nuts and bolts) to extremely large and heavy items that need to be moved with an overhead crane. In response, Storage Solutions implemented a combination of bin shelving to handle the small parts storage, hand-stack rack locations for medium-sized products, and full pallet rack storage locations and decked cantilever for oversized and odd-sized products. Also, heavy-duty outdoor racking was installed for products stored in the yard.

SSI also completed all floor striping for bulk lanes, staging lanes, pedestrian aisle ways, and overhead signage. Miscellaneous additional solutions provided include:

  • Overhead Cranes – to move hefty products (over 10,000 lbs)
  • Floor Scales – to weigh inbound/outbound shipments with a capacity of up to 20,000 lbs.
  • Power Mobile Carts – to optimize worker efficiency for inbound receipt and outbound labeling process
  • Pack Stations – to optimize worker efficiency during pack out of small parcel and less-than-truckload (LTL) orders

Want to learn more about past projects we have completed? Check out other case studies from a variety of project types across several industries. Let Storage Solutions be your simple, smart, and strategic partner for any of your upcoming project needs!

push back pallet rack system

To put it simply, it depends! Lots of factors come into play when deciding what type of pallet rack best suits your operation.

  1. Cost
  2. Size of the facility
  3. The clearance height of the facility’s ceiling
  4. What type of product is stored
  5. Size of pallets used
  6. What is the product turn around
  7. What kind of forklift truck used

Knowing this information can help you determine what solution will work best in your facility. 

Pallet Rack 101:

Roll Formed and Structural

A roll-formed pallet rack is the most common construction of racking. It is usually manufactured in the “teardrop” style; teardrop referring to the teardrop-shaped holes on the uprights column. It is cold rolled and typically has a rivet connection. There are few circumstances when roll-formed has a bolted connection. This type of pallet rack also tends to be less expensive because it is comprised of less steel than structural. Roll-formed uses mounting clips that can easily be adjusted to different heights according to load size, which is beneficial for warehouses that store a wide variety of product sizes.

Structural pallet rack is hot-rolled. Its components are almost always bolted together, which can easily spot structural versus roll-formed pallet rack. The horizontal load beams connect to the uprights with bolts, which increases the rack’s weight-bearing capacity. The structural pallet rack is made of thicker steel c-channels, making it the more expensive but durable pallet rack option. It is most commonly used in warehouses where inventory has a quick turnover because durability is a huge factor when accommodating heavy forklift traffic.

Uprights

  • Vertical bracing columns
  • Depth determined by product size
  • Height determined by clear height in building and forklift capabilities
  • Column size determined by capacity needed
  • The capacity of uprights determined by the spacing of beams – spacing beams far apart can create bends in the uprights, closer together makes it stronger
  • Gauge determined by capacity needed

Beams 

  • Horizontal load supports
  • Length determined by product size
  • Height determined by capacity needed
  • Gauge determined by capacity needed – lower gauge means thicker steel and higher capacity
  • Deflection in beams is how much the beam is designed to bend – deflection is typical!

Row Spacers

  • Flue space connector
  • Layout determines the length of the row spacer
  • Length determined by flue space dimensions
  • Type determined by upright to be connected to
  • Some row spacers are not interchangeable, so be aware when selling used equipment

Pallet Supports

  • Load supports connecting front and back beams
  • Length determined by the depth of upright
  • Style and gauge determined by capacity needed

Wire Decking

Wire decking is used in pallet racks and other types of storage racks. Made from steel wire, wire decking gives you the flexibility to store a variety of pallet sizes. It provides a stable surface while also maintaining an open surface, which improves fire safety by enhancing your overhead sprinkler system’s performance. Wire decking is easy to install and is virtually maintenance-free.

If you have additional questions, give us a call at 866.474.2001 or contact your sales representative!