Transform Your Carolina Warehouse with Carton Flow

Carton Flow Rack: The Super-Solution for Your Warehouse

You might think you know everything about carton flow rack—it’s been a warehouse staple for decades, after all. But you may be surprised to learn that it’s one of the most rapidly evolving tools in warehousing today—and it could be the solution to a challenge in your Carolina facility. Over time, this rack has transformed into a super-solution, enabling operations to adapt to the changing demands of e-commerce, SKU proliferation, just-in-time inventory, and more!

Perhaps the carton flow you recall had only single lanes with generic wheeled tracks. While the basic concept remains the same, the design and functionality have significantly evolved. Carton flow rails attach to standard pallet racks and are set at a slight downward pitch from the rear loading aisle to the forward picking aisle. This configuration separates loading and picking activities, reducing congestion and fostering a safer work environment.

Today’s systems can be fully customized to match your picking application needs, allowing you to optimize warehouse space, increase capacity, and enhance picking speed and accuracy. The two primary styles are roller rails and wheeled sections. Roller rails are ideal for uniform carton or tote sizes, while wheeled designs create a bed of tracks that can accommodate SKU lanes of any width

The Essentials   

Carton Flow Rails
Carton flow rails with single-width wheels or rollers allow for fully customizable solutions. These rails come in varying widths and installation options to fit your needs.

Wheeled flow rails are available in either steel or heavy-duty composite, making them adaptable to different warehouse climates, conditions, and load weights. With this flexibility, you can create a tailored gravity flow system.

For packaging with consistent sizing, full roller carton flow is the best option. It is available for lightweight, medium, and heavy-duty applications, offering a reliable and efficient solution.

For a budget-friendly choice, roller track carton flow uses rollers mounted on a wider bed rather than individual rails. This option works well as a stand-alone carton flow system or as part of an in-rack configuration.

Full-Wheel Bed Carton Flow Tracks
When inventory sizes vary or frequent reprofiling adjusts your SKU layout, drop-in tracks are the go-to solution. These tracks create a continuous wheeled surface from edge to edge, allowing for SKU lanes of any width while maximizing the use of the storage bay. Tracks can be mounted either flush or pitched, depending on operational requirements.

Applications:

• Pick Modules
  Pick modules are multi-level stations that integrate carton flow into your existing pallet rack for ergonomic picking. Loading and picking occur in separate aisles, reducing traffic and enhancing safety in high-activity areas. With deep SKU lanes and automatically replenished pick faces, pick modules boost pick rates and improve cycle times. Many modules also incorporate conveyors and full pallet storage, keeping reserve inventory close for efficient restocking.
• Floor-Level, In-Rack Carton Flow
  Floor-level carton flow is an excellent way to eliminate dead space caused by partially full pallets, increasing the number of pick faces available. This setup is ideal for slower-moving SKUs and inventory that requires partial picks.
• Stand-Alone Carton Flow
  Stand-alone carton flow systems are a flexible, mobile solution for temporary or seasonal order picking and light manufacturing assembly. These units are easy to push or tow into place and just as simple to store when not in use. Offering easy assembly, affordability, and ergonomic benefits, they provide an all-in-one solution for dynamic inventory needs.

CUSTOMIZED CARTON FLOW:

Like any superhero, carton flow becomes even more effective with the right accessories. Manufacturers have developed innovative solutions to adapt carton flow systems for nearly any type of racking, packaging, picking methods, or technologies. Here are some of the most common and creative accessories:

Customized Accessories:

• • Load-Side Impact Trays: These trays protect wheels and rollers from damage caused by dropping inventory directly onto the flow rack. Items placed on the impact tray slide easily onto the flow rack, progressing to the opposite aisle for picking. Impact trays help prevent wheel and roller damage, reducing downtime and replacement costs.
  • Pick-Side Trays: These trays attach at the pick aisle and can be angled to improve worker ergonomics and enhance product visibility for more efficient picking.
  • Layback Frames: More than just an accessory, layback frames feature a slanted design that exposes the front carton position on all levels, making picking easier and more accessible. The staggered shelf design also improves overall visibility and efficiency.
  • Entry Guides and Lane Dividers: These accessories define SKU lanes, enabling faster and more accurate loading and picking. Full-length dividers are ideal for separating awkward or tall SKUs and ensuring complete product separation. Entry guides (or flags) can be positioned anywhere on the wheeled bed, often at the load and pick sides, to provide a clear visual of SKU lanes and improve picking accuracy.

 

We know that was a lot to take in, but what other storage solution offers the same speed, accuracy, and ergonomic benefits for case, tote, and individual item order picking? Apex Carolinas is your go-to source for all your warehousing needs. Our team has extensive expertise in carton flow systems and can help design the perfect solution tailored to your specific requirements. One call does it all!