Boost Your Pallet Flow Rack Performance with These Simple Accessories
Maximize Efficiency with Pallet Flow Rack Accessories — Separators, Speed Controllers, Pallet Stops & More!
Pallet flow rack is a gravity flow storage system used in various common warehouse applications. From high-density, multi-level pallet storage to high-volume case picking, mixed-SKU pallet building, and even dock intake and staging… pallet flow rack is an incredibly versatile solution.
The flow function of pallet flow comes from wheeled or roller tracks placed at an incline within standard racking. You can also floor-mount the rails for a cost-effective, low-profile design. Several manufacturers offer a range of products, including hearty composite wheels, steel wheels, and roller options. The inclined rail position is the key to engaging gravity to take over and flow the pallet from the load side to the opposite pick side. The separate load and pick aisle access can be beneficial for minimizing aisle congestion to support efficient processing.
Pallet flow is a FIFO system ensuring your inventory’s first-in/first-out rotation. This feature makes pallet flow a favorite among food and beverage processors, distributors, and any industry with dated perishable goods. The significant load capacity of flow racking is also favorable, with some configurations safely managing 5000 lb pallets. Note, however, the word “safely.” With such a variety of design possibilities, significant load capacities, and shear volume, the safe design of your pallet flow system is imperative. Customized accessories enhance the performance and safety of your pallet flow rack.
Pallet Flow Rack Accessories
- Pallet Separators/Retainers
- Speed Controllers/Braking Devices
- Lift Tables
- Maintenance Panels/Decking
- Entry Guides/Centering Guides
- Pallet Stops
Pallet Flow Separators
Pallet separators, also called pallet retainers, create space between the front pallet at the pick aisle and the rear pallets in the lane by holding back the rear pallets in the lane. The separation can vary from 4” to 12” depending on the application, but it helps eliminate the pressure from the rear pallets absorbed by the front pallet. Back pressure can be significant in deep lanes and may exceed forklift mast capacity at higher elevations. Back pressure is also a hazard in case picking, where the empty pallet must be removed from the lane by hand.
The RMI calculated back pressure as approximately 6% of the combined weight of the rear pallets.
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For example, in a 4-deep system with 2,500 lb pallets, the combined weight of the rear pallets is 7500 lbs. .06 x 7500 = 450 lbs of back pressure. |
Several styles of separators exist to meet your application needs. Case pick separators are foot pedal triggered to release the rear pallets once the worker has removed the empty pallet and the front position is clear. In forklift applications, the rear pallets release automatically when the front pallet is removed. Other separator designs facilitate robotic arm or crane picking, and one is uniquely designed to flow empty pallets away from the pick aisle. In general, however you decide to use your pallet flow rack, the Apex team can ensure you do it safely.
Speed Controllers & Braking Systems
Slowing pallets as they flow to maintain a safe, smooth speed is the job of the speed controllers, also known as pallet flow brakes. Various styles and mounting options exist to enable customers to tailor their pallet flow rack design to their inventory processing needs. Some braking mechanisms make direct contact with the pallets, while others reverse the flow of the rollers to slow the advancing pallets.
An added benefit of speed controllers is that they help keep the pallet centered in the lane as it flows –particularly critical the deeper the lane. This prevents the pallet from getting stuck and helps the forklift operator properly access the pallet for removal from the lane.
 Top View |
 Underneath View |
Lift Tables
Pallet flow rack is advantageous in quick-turn, high-volume case-picking applications. The flow lanes continuously feed inventory to the pick aisle, and restocking can be done anytime from the outside aisle.
Pallet flow lanes can incorporate lift tables at the pick aisle position to improve ergonomic positioning and reduce worker strain. Pneumatic options enable workers to raise or lower tables quickly with a foot pedal or remote control. Hold-back devices in the flow lane are critical in stopping pallets from advancing onto the table until adequately lowered.
Talk to your Apex representative about how lift tables can improve case-picking productivity and minimize worker strain and associated costs.
Maintenance Planks
Adding decking panels, or maintenance planks, between pallet flow rails creates a solid surface to satisfy maintenance and safety requirements. An economical choice is a perforated metal deck such as bar grating or punch decking. These options allow light and water through but prevent pallets or items from falling through the rack.
It’s important to note that the decking is not suitable for walking on. If there is a pallet hang-up or debris in the lane, please see our Maintenance Guide and Forklift Training Video for safe step-by-step directions. Talk to our team about the best options for your pallet flow design and inventory needs.
Pallet Flow Entry Guides
Entry guides, also called centering guides, help the forklift operator position the pallet when loading into the lane. They provide a visual guideline to center the pallet, setting it off for successful flow. Guides are customizable and can be mounted between lanes in dual-lane configurations or on either side of single lanes. Painting the guides a bright color also helps the drivers spot the guide, particularly on upper levels of tall systems.
Pallet Stops
Durable, angled steel stops help pallets slow and hold at the end of the lane. Whether you have wheeled or roller rails, pallet stops are valuable to your pallet flow design. Painting the stops a bright color also helps the forklift operators locate the pallet efficiently. Finishes also include galvanized for washdown compliance.
Ask your Apex team about bolt-on pallet stops that are easy to replace if damaged versus styles integrated into the rail.
Pallet Flow Rack Expertise… Look No Further Than the Apex Team
Pallet flow rack is a common application for many Apex customers. It’s space-saving, labor-reducing, hard-working, and, overall, easy to use and maintain. Let our systems designers help you create the solution that will produce the most effective results for your team. Quality products and great design will take you to your goals — We Got This!
