Carton flow is a storage and picking system designed to optimize warehouse operations. It utilizes gravity to move hand-loaded inventory from the back of the system to the front, consisting of inclined roller tracks or lanes that allow products to flow smoothly from the loading end to the picking end. This design makes it ideal for managing a large variety of SKUs that are picked in quantities less than a full pallet. This system is specifically designed for handling smaller units, such as cartons, totes, or cases. Implementing this storage system can lead to improved efficiency, increased productivity, a reduction in labor expenses, and up to a 50% increase in storage capacity for most products. Additionally, it enhances inventory control and visibility for stored items, eliminating the uncertainty related to shelf life dates and ensuring that older items are picked first.
There are several styles of Carton Flow racks, they include:
- Traditional Carton Flow: The most common. These racks consist of slightly inclined wheel and roller platforms that gravitate stock toward the picker
- Span Track: This system features full-width aluminum or galvanized steel roller tracks
- Dura-Flex: Pre-assembled tracks designed to drop into existing pallet rack structures, offering an affordable and flexible solution
- Quik Pik Style: A traditional style with plastic wheels embedded in u-shaped metal tracks
When choosing a carton flow system for your facility, it is essential to select the appropriate system based on the size and weight of the products being stored, as well as the desired level of customization. Carton flow racks maximize storage capacity by utilizing the full height and depth of pallet rack shelves, and they can be configured to accommodate various load sizes and types. This makes them suitable for a wide range of industries and applications. These systems promote ergonomic picking and implement a FIFO (First In, First Out) method, ensuring that the most popular items are always located within the “golden zone,” while the oldest items are picked first. This simplifies your inventory management. When designing these systems, be sure to schedule regular preventative maintenance to ensure that the carton flow system maintains peak longevity and effectiveness.
Contact us to get started on the design and installation of a Carton Flow system for your facility.
