High-density rack with inclined roller tracks allowing pallets to flow forward by gravity, automatic FIFO.
Detailed Definition
Pallet flow rack is a high-density pallet rack system in which each lane is a gently sloped track of rollers or wheels. Pallets are loaded at the higher end and roll forward by gravity to the picking face, so the first pallet in is the first out. Brakes or speed controllers keep pallets moving at a safe speed, and a separator at the exit holds back the line so the front pallet can be removed without pressure from those behind. It suits SKUs with many pallets each and steady demand.
Pallet quality matters more in flow rack
A pallet in a flow lane rides on rollers instead of resting on beams, so its bottom deck has to roll smoothly. Broken or missing bottom boards, protruding nails and warped boards can stop a pallet in the lane, and clearing a jammed lane is slow and can be hazardous. Rack makers usually state which pallet type, size, orientation and bottom deck design the lanes are built for, along with weight limits. Mixing pallet types in one lane causes trouble because different bottoms roll differently.
Planning a flow rack system
- Base the design on the actual pallets used, including their weight range and bottom deck style.
- Keep loading and picking aisles separate, which is part of how FIFO is maintained.
- Plan on one SKU per lane in most cases, and size lane depth to the number of pallets per SKU you expect to hold.
- Provide safe access for clearing a stuck pallet, following the manufacturer's procedure.
- Follow ANSI MH16.1 and the manufacturer's instructions for the structure, and inspect brakes and rollers regularly.
Compare with push-back rack, which is loaded and unloaded from the same aisle and works last-in, first-out.
Related Glossary Terms
Frequently Asked Questions
What pallets work in pallet flow rack?
Use the pallet type the system was designed for. Lanes are usually designed around a specific footprint and bottom deck layout, often with bottom boards running in a set direction relative to the rollers. Pallets should be in good repair with no broken or missing bottom boards and no protruding nails. Recycled pallets can work if they meet the same condition rules. Get written pallet requirements from the rack supplier before buying pallets for a flow system.
Is pallet flow rack FIFO or LIFO?
Pallet flow rack is first-in, first-out. Pallets are loaded at the back, higher end of each lane and picked from the front, lower end, so the oldest pallet always reaches the picking face first. That makes it a good fit for dated or perishable goods. Push-back rack, which loads and unloads from the same aisle, works the other way round, last-in, first-out.