Case & Carton Flow Rack Guide

case and carton flow racking guide

Case & Carton Flow Rack Guide

What Is Case Flow Racking?

Case flow racking, also known as carton flow racking, is a flow racking system designed for picking inventory efficiently and accurately. It uses an inclined conveyor of wheeled tracks to allow cases easily move along a sloped plane.

Benefits of Carton Flow Racking Systems

Enhances Storage Density

A case flow rack is a high density storage system that stores more inventory in the space.

Organizes Inventory

Inventory remains better organized and easier to find or pick, reducing order preparation time.

Maintains FIFO Inventory Flow

Carton flow racking automatically rotates products on a first-in, first-out basis. The FIFO system makes it easier to have high product turnover rates and ideal product rotation.

Reduces Labor Costs

Labor savings of up to 75% can be realized.

Minimizes Maneuvering & Displacement

Carton flow systems have more pick faces at the front of the racks, allowing workers to reduce their maneuvering and displacement times to take short, efficient routes through the racking.

Maximizes Pick Faces

In order pick areas, case flow racks increase the number of pick faces. SKU pick faces are maximized because only one case or carton of each SKU is presented to the picker per lane. Incorporating pallet racks and mezzanine racks further enhances pick faces.

Increases Pick Accuracy

Pick accuracy is enhanced when carton flow racks are combined with a pick to light (PTL) system that guides workers through the racking using lights. The product location reduces the extraction time required for loads.

Separates Picking & Stocking

Case flow racks avoid interference in material preparation and restocking tasks while ensuring FIFO order fulfillment is productive. This system minimizes operator and picking interference because picking is performed on one side of the rack system, while restocking is performed at the opposite end of the racking system. SKUs can be replenished without interfering with order picking operations. Forklift operators can pick and stock items without interference and with minimized travel. They can pick the first item loaded to support the FIFO system, keeping reserve storage in the rear cases.

How to Operate a Case Flow Rack

A carton flow system has a base frame and uprights made from beams with several guide rails and entry, exit, and side profiles. Each load face has rollers to move the inventory and separators to keep like SKUs together. Braking systems can be implemented to control the speed.

With case flow, merchandise is stocked in the rear of the carton flow rack and moves toward the picking station in front on an inclined shelf equipped with a specially designed roller track. When a carton is removed from the picking station, the next one in line rolls to the front; also known as indexing. The load and pick aisles are separated on opposite sides of the racking system.

Contact Us To Learn More

Carton flow racking systems keep inventory organized and save on labor costs, and Twinlode Automation implements case flow racking systems for warehouses in various industries. We have years of experience with pallet rack solutions. Twinlode Automation also offers professional services for assistance with consultation, design, and implementation.

To learn more about carton and case flow racks for your warehouse, contact us online.