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Maximizing Space and Efficiency with Gravity Flow Solutions in Your Warehouse
In today’s fast-paced world of warehousing and distribution, optimizing space and increasing productivity are more important than ever before. Implementing gravity flow racking solutions such as Pallet Flow Rack (FIFO), Push-Back Rack (LIFO), or Carton Flow Rack can help achieve these goals – while also reducing labor and equipment costs.
Pallet Flow Applications:
Pallet flow is a high-density storage system that maximizes cubic space and enables efficient inventory rotation. It’s ideal for high-volume SKU consolidation and can be designed for FIFO or LIFO inventory rotation.
Pallet flow is a storage system designed for storing pallets in a deep and organized manner. In this system, the pallets are loaded onto specially designed pitched flow tracks, also known as rails, on the higher side of the lane by a forklift. The pallets then flow down to the lower end of the lane, where they can be easily unloaded by a forklift.
Pallet Flow rack (also known as Flow Through Pallet Rack), can be configured as a FIFO system where the loading area is at the opposite end of the unloading area. To help understand the FIFO storage concept better: the next time you are picking up milk from your local grocery store, take a look at the milk racks, where cartons are picked up by the consumer at the lower end and fresh cartons are loaded in the rack from inside the cooler on the higher end. This system ensures that the stock is rotated regularly, following the “First In, First Out” (FIFO) system, which is particularly useful for date-sensitive products.
Each lane of Pallet Flow Racking can hold several pallet positions deep and high. Lanes can be installed adjacently, making them as wide or narrow as necessary.
“Last In, First Out” or LIFO storage can also be achieved with a Push-Back Rack Flow System. This type of Push-Back system is designed using pallet flow rails or rollers. Push-back racking has a single loading and unloading area, at the front of the rack, and the unit loads are stored by pushing the previous ones toward the back of the rack:
- Forklifts load pallets onto a lane. Each lane typically comprised of 2-3 rails per lane
- When another pallet is loaded into the lane, the first pallet is pushed back towards the back of the rack. This process continues until the last pallet is loaded
- When unloading the pallet rack, this sequence is reversed. The rails are inclined toward the aisle, so when the operator picks up the pallet resting on the rails and backs out, the remaining pallets will flow to the front of the lane. They can then remove each pallet in succession until the lane is empty.
Some common pallet flow applications include:
- High-density Pallet Storage FIFO (Flow Through Pallet Rack)
- High-density Pallet Storage LIFO (Push-Back Pallet Rack)
- Case Picking
- Layer Picking
- Assembly Lines
- Raw Materials Supply
- Pallet Intake and Dock Staging
- Empty Pallet Returns
One of the advantages of Pallet Flow Rack and Push-Back Flow Rack is they can handle a variety of pallet sizes and weights, and can be customized to fit the specific needs of your operation. By enabling automatic pallet flow and minimizing the need for labor, Pallet Flow Rack systems can significantly improve pick rates and accuracy, while also reducing equipment and labor costs.
Carton Flow Rack is the same concept as Pallet Flow, but on a different scale. Carton Flow Rack is mainly used in distribution warehouses for fast fast-moving items. Flow lanes are customized to individual SKUs. A Carton Flow System can help increase product deployment speed and efficiency. This type of system can help improve your pick rates and reduce labor costs.
Carton Flow Rack is a versatile gravity flow solution that’s ideal for e-commerce fulfillment, full carton picking, broken case picking, kitting, and finished goods packaging. Some common carton flow applications include:
- eCommerce Fulfillment
- Full Carton Picking
- Broken Case Picking
- Kitting
- Manufacturing Parts Assembly
- Finished Goods Packaging
These systems typically feature separate load and pick aisles, with a pitched lane design that promotes concurrent functions and automatic stock replenishment. Single SKU lanes support accuracy and enable workers to quickly identify low stock inventory for efficient restocking.
Carton Flow can handle a wide range of inventory styles and sizes and can be customized to fit the specific needs of your operation. By enabling automatic carton flow and minimizing the need for labor, carton flow rack can significantly improve pick rates and accuracy, while also reducing equipment and labor costs.
- Save up to 50% space compared to static racks and shelving
- Carton flow systems can increase pick slots – up to 40 locations per bay
- Because more SKUs can be presented for picking in a bay of rack it reduces travel with a reduced pick path - increasing throughput.
- Decreasing the walking and searching time for pickers can slash labor costs by as much as 50%
- Improves picking and putaway productivity
Conclusion
In conclusion, gravity flow solutions offer a variety of advantages for businesses looking to maximize space and increase efficiency. With a variety of solutions available, including pallet flow and carton flow applications, businesses can choose the best option for their unique needs. Whether you’re looking to streamline your eCommerce fulfillment process or improve your manufacturing and assembly operations, gravity flow storage solutions are a smart investment.
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