Pallet flow is a high-density storage system designed to store pallets efficiently. It utilizes gravity along with wheels or rollers to convey and accumulate pallets, allowing them to move from loading to unloading automatically. This system is ideal for optimizing space and ensuring effective inventory turnover through the FIFO (first in, first out) method, which is particularly advantageous for inventory containing a limited number of high-volume SKUs.
The design of the system is compact, allowing for a high number of pallets to be stored in a small area. It can accommodate between 2 to over 20 pallets deep, effectively doubling the capacity compared to other racking systems. This results in extremely high-density storage and maximizes the utilization of surface area in a warehouse.
Pallet flow systems are useful for case picking and help store items efficiently. They automatically refill the pick area when an empty pallet is taken away, providing dense storage. These systems can save up to 60% more space than traditional pallet racks, reducing the need for floor space and increasing storage capacity. By using pallet flow, workers spend less time searching for products and handling them manually, which saves time and labor. These systems can be customized to fit any warehouse layout, making them great for high-density storage and quick order picking. They also adapt to different types of loads, including various pallet sizes, half pallets, metal containers, and boxes. The design allows for loading pallets from the back and picking them from the front. This setup creates forklift aisles at both ends of the racks, cutting down on unnecessary forklift travel and allowing operators to load and unload pallets more efficiently.
There are different types of pallet flow racks, each suited to specific operational needs.
- Full-Roller System: Ideal for handling non-uniform or mixed-size pallets with ease. Full-width steel rollers are used which provide a broad surface for pallet movement. They enhance adaptability to various pallet types. This design is useful for warehouses dealing with diverse inventory.
- Split-Roller System: Useful for uniformly sized loads and heavier-duty applications. These systems balance adaptability with cost efficiency when 100% pallet support isn’t required.
In some configurations, individual skate wheels are used to provide more support to the strongest part of the pallets, ensuring a controlled flow. This track configuration is best used in scenarios where pallets are uniform in size and weight
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