Pallet Flow Racking (also known as Gravity Flow) is a high-density storage system that uses inclined rollers and gravity to move pallets automatically. It is the ultimate solution for FIFO (First-In, First-Out) stock management.
Key Benefits
- Perfect FIFO: Guarantees that the oldest stock is picked first, which is critical for perishable goods.
- High Throughput: Separates loading and unloading aisles, allowing forklift drivers to work simultaneously without getting in each other’s way.
- Space Saving: Eliminates multiple aisles, potentially doubling your storage capacity compared to selective racking.
- Energy Efficient: Operates entirely on gravity—no electricity required for movement.
Considerations
- Higher Initial Cost: The complexity of rollers, brakes, and separators makes this more expensive than Drive-In or Push Back systems.
- Pallet Sensitivity: Requires high-quality, standardized pallets. Damaged boards or loose nails can cause jams in the roller lanes.
- Height Loss: Because the lanes are inclined, you lose some vertical clearance at the back of the rack compared to flat systems.
How It Works
- Gravity Tracks: The racks are equipped with roller lanes tilted at a slight angle (usually 3-5%).
- Loading: Pallets are loaded from the rear side (the higher end) of the system.
- Flowing: Gravity causes the pallet to slide forward over the rollers toward the front picking face.
- Speed Control: Integrated braking rollers control the speed of the pallets to prevent collisions or damage.
- Unloading: Pallets are retrieved from the front side. As one is removed, the next one slides into its place.
Ideal For
- Perishables: Food, beverages, and pharmaceuticals with strict expiration dates.
- High-Volume Items: Products that move in and out of the warehouse very quickly.
- Buffer Storage: Great for staging areas between production and shipping.