Making the Case for Case Picking with Carton Flow Rack
Dynamic Carton Flow Rack is Your Front Line for Productive Order Picking
Managing an increase in demand for smaller, individualized orders is one thing. Couple that with a labor shortage, rising wages and operational costs, and an industrial space shortage, and you’ve got a potential crisis in the making. However, there’s a relatively simple way to help you manage that order processing demand and those other issues while delivering measurably improved function overall –It’s called carton flow rack.
Carton Flow Advantages
- Organizes high-volume SKUs in orderly pick lanes
- Consolidates pick zone to reduce travel time
- Increases storage up to 50% vs. static rack or shelving
- Saves labor costs – up to 75% vs. static rack or shelving
- Adds pick locations – up to 40 locations per bay
- Positions cases, cartons, and totes, for quick, ergonomic reach
Like the Carolina shoreline waves, carton flow rack is dependable. The system is comprised of wheeled or roller rails that conveniently drop into standard racking. As inventory is loaded, it flows down on a gentle pitch to the opposite side pick aisle. The deep lane design provides a ready supply of inventory right in the lane that automatically refills the pick face. Each SKU lane is easy to see and can be separated with lane dividers if needed (see photo at top). Carton flow rack is also compatible with warehouse automation such as pick-to-light, robotic picking, and wave/batch-picking applications.
Designing Your System
You have choices for flow rack design which is mostly predicated on the specs of your inventory. There are wheeled or roller tracks to choose from based on whether you have same-size or varying-size items.
Wheeled rails – Create a full bay of flow rack with wheeled rails. This lets you segment SKU lanes of varying sizes side-by-side while still maximizing your bay space.
Roller tracks – Roller tracks are closely paired with the width of the inventory and thus better used with same-size cartons or totes.
Wheeled carton flow options
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Roller carton flow options
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Whichever design you choose, you can find products suited for light-, medium-, or heavy-weight loads.
Carton Flow Rack Accessories
A number of accessories can be applied to your carton flow design that will enhance usage and support pick speed and accuracy.
Impact trays – Protect your wheels and rollers from damage incurred by repeatedly loading heavy inventory directly onto the carton flow rails. Steel impact trays mount between the beam and the edge of your flow rails to take the hit and allow for an easy push into the lane.
Angled trays – Give your workers a better view and more ergonomically supportive positioning for picking with angled trays. Trays can be tilted at any pitch and are customizable to fit your unique system design.
Entry guides – Heavy-duty guides provide a visual marker for workers to improve accurate loading or picking. With a quick snap and click, you can create segmented SKU lanes or move them along the bay for fast reprofiling.
Full-length dividers – Depending on your inventory, it may be necessary to distinctly separate SKUs –that’s where full-length dividers are invaluable. The slim profile ensures you get the most from your carton flow rack and keep your SKUs clearly divided.
Layback Frames – Another way to enhance access to the pick levels is to use a slanted frame. This design staggers each level for easier picking.
Application Options for Your Carton Flow Rack System
Standalone carton flow rack systems may be just what your operation needs; however, carton flow rack is often paired with pallet storage rack in a pick module design or within pick tunnels to maximize the use of vertical and floor space.
- Pick module – Create a high-density storage and optimized order picking zone with full pallet storage, carton flow rack, and conveyor. Pick modules minimize worker travel time and facilitate faster pick rates with orderly, efficient SKU storage in a concentrated area. You can add static shelving for slow movers as well.
- In-rack carton flow – Convert low levels of underutilized pallet rack to carton flow. Low-profile carton flow helps maximize available space between rack levels.
- Mobile carton flow – Carton flow on the go! Mobile carton flow carts are ideal for quick response to production shifts, manufacturing assembly changeovers, kitting applications, seasonal picking, and more. The units are compact, easy to move, and store away when they’re not needed.
The Easiest Decision to Make
Carton flow rack may be the solution you need to get your order-picking operation… well, in order! But how do you know for sure? You call your local Apex Carolina experts – whether you’re located in Charlotte or Hickory North Carolina, or Greenville South Carolina. We are your local source for all things warehouse and distribution. Our warehouse and storage experts will provide the best options to maximize your space, workforce, and equipment to meet your inventory processing needs.
Contact our team today and ask for a free consultation or site visit. We look forward to the opportunity to work with you.
