Optimize Space, Pick Rates & Accuracy - Carton Flow Rack Does It All
Carton flow rack is a gravity-fed storage system for cartons, totes, and individual items. It installs into standard racking and can be used as a stand-alone, ergonomic pick zone or as part of a pick module. Cartons are loaded and flow on slightly inclined rails to the opposite aisle for picking. The system separates picking and replenishment activities to save up to 75% labor costs vs. static storage. First-In/First-Out (FIFO) inventory rotation minimizes shelf time and keeps inventory fresh.
Advantages | Considerations
- Organizes SKUs for fast, accurate picking
- Saves space – up to 50% vs. static rack or shelving
- Reduces labor costs – up to 75% vs. static rack or shelving
- Increases pick locations – up to 40 locations per bay
- Efficiently process inventory with FIFO rotation
Call the Apex warehouse design team for a free consultation, and let’s talk about your inventory storage and processing goals.
Orderly and Ergonomic - Carton Flow Accessories Deliver Results
Carton flow rack is all about organization and speed. Here are a few easy to install accessories that enhance your system operation and help your team meet your inventory processing goals.
Carton Flow Accessories
- Lane dividers
- Entry guides
- Knuckle shelf
- Load impact shelves
Lane dividers
Keep SKUs organized and easy to spot and pick. Lane dividers also satisfy regulatory requirements for inventory that must be kept separate.
Entry guides
Cost-effective tool for helping workers quickly identify SKU lanes and accurately load inventory. They pop on and off for easy reprofiling.
Knuckle tray
Angled shelf that can be positioned to make it easier to see and pick inventory.
Load impact shelf
When loading heavy cartons into a carton flow rack it is better to install impact shelves to take the brunt of the initial impact and spare your valuable flow rails from damage. Easy customize and install.
The Apex team will help you equip your carton flow rack to meet all your order picking goals. Call today for a free consultation.
Carton Flow Rack Evolves into Valuable Order Picking Tool
The carton flow racking of the past consisted of individual lanes of the relatively generic wheeled track. Jump ahead to today and find a system that serves as space-saving, dynamic inventory storage manufactured with superior materials. Carton flow rack meets a specific need for accessing carton, case, and tote inventory quickly and accurately. It can be accessorized to improve flow and maintain orderly SKU lanes, and it is often the centerpiece of optimized pick zones to maximize labor resources and warehouse space. Check out our blog:
The Evolution of Carton Flow Rack Rolls-on… Raising Up a Super Warehousing Tool to learn more.
The Apex engineering and design team is available to help you choose the right carton flow products for your warehouse space, budget, and order picking needs; just give us a call today!
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FREQUENTLY ASKED QUESTIONS
What is a carton flow rack, and how does it work?
Carton flow rack is a gravity-fed storage system that uses inclined rollers or wheels to move cartons, cases, or totes from the loading aisle to the picking aisle. It supports First-In, First-Out (FIFO) inventory rotation and separates replenishment from picking to improve picking efficiency and reduce congestion. The system works best in high-volume case-picking applications and should be designed for the product’s size, weight, and SKU profile.
When is carton flow rack the best storage solution?
Carton flow rack is best for operations that pick full cases, split cases, or totes with medium to high order volume and frequent SKU access. It is commonly used in distribution centers, e-commerce fulfillment, food distribution, and manufacturing. The system performs best when inventory moves consistently through the pick face. For slow-moving reserve inventory or full-pallet storage, another rack configuration may provide better space utilization and lower investment.
Can carton flow rack be installed in existing pallet rack?
Yes. Carton flow rack can often be installed within existing selective pallet rack by adding gravity flow lanes comprised of wheeled or roller tracks. This approach allows facilities to create ergonomic picking locations without replacing their entire storage system. Compatibility depends on rack dimensions, beam capacities, inventory characteristics, and the desired picking configuration, so an engineering review is recommended before retrofitting an existing system.
What products can be stored in carton flow rack?
Carton flow rack is designed for cartons, corrugated cases, plastic totes, and other unit loads with stable bottoms that can roll smoothly on wheels or rollers. The appropriate flow lane depends on product weight, carton dimensions, bottom surface, and packaging consistency. Irregular, soft-bottom, or unstable loads may require different track styles, accessories, or an alternate storage solution to maintain reliable product flow.
How does carton flow rack improve order picking efficiency?
Carton flow rack improves order picking efficiency by automatically presenting inventory at the pick face as products are removed. Separating replenishment from picking reduces travel time, minimizes congestion, and keeps pick locations stocked for continuous order fulfillment. Performance depends on proper slotting, SKU velocity, and overall warehouse layout.
What should be considered when designing a carton flow rack system?
A successful carton flow rack design starts with understanding carton size, weight, SKU mix, replenishment frequency, and picking methods. Flow lane width, roller or wheel selection, lane slope, ergonomic reach zones, and accessories such as lane dividers or impact shelves all influence system performance. Designing around actual inventory characteristics helps maintain smooth product flow while reducing jams, product damage, and maintenance requirements.
What is the difference between carton flow rack and pallet flow rack?
Carton flow rack is designed for cartons, cases, and totes that are picked by hand, while pallet flow rack stores full pallet loads moved by forklifts. Both use gravity and support FIFO inventory rotation, but they serve different handling methods and inventory levels. Operations that replenish case-picking locations from pallet storage often use both systems together to improve throughput and space utilization.
What accessories can improve carton flow rack performance?
Carton flow rack accessories such as lane dividers, entry guides, impact shelves, and ergonomic pick trays help improve organization, protect flow lanes, and support faster, more accurate picking. The right accessories depend on carton sizes, SKU variety, and picking methods. Facilities with changing inventory profiles often benefit from adjustable components that simplify lane reconfiguration as operational requirements evolve.
Does carton flow rack support FIFO inventory management?
Yes. Carton flow rack is designed to support First-In, First-Out (FIFO) inventory management by loading products from the rear and presenting the oldest inventory at the front pick face. FIFO is especially valuable for products with expiration dates, lot control requirements, or frequent inventory turnover. Proper lane design and consistent replenishment practices are important for maintaining reliable inventory rotation.
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