Pallet Flow Racking


Pallet flow racking is a type of storage system that uses gravity to allow palletized loads to move forward along a sloped lane for easy picking. Pallet flow racks increase product flow to a pick face and are ideal for first-in, first-out (FIFO) stock scenarios.  Pallet flow racking is a great way to maximize storage space for single SKU lanes.


Twinlode Automation designs pallet flow systems to meet specific client needs and analyzes inventory data to determine lane depths. Various options such as wheel type and size, wheel pattern configuration, simple braking or even heavy duty braking used in the deep lane system. Pallet flow systems are the ideal combination of flexibility and adaptability that can be used in both large-scale and small-scale operations for fast-moving, full pallet loads.


First-In, First-Out Racking Systems


FIFO racking systems allow the first pallet placed in the system to be the first pallet removed. On a pallet flow rack, the pallet moves to the front when it is placed in a lane.


Applications for a FIFO racking system include industries that:


  • Have items with expiration dates.
  • Have a high turnover rate for inventory.
  • Need rapid inventory rotation.


Pallet Racking for High-Volume Operations


Pallet flow racking stores palletized loads efficiently by reducing the area required for warehouse storage. By using pallet flow racks to create a high-density environment, the warehouse’s storage capabilities and throughput improve.


The advantages of pallet flow racking for high-volume operations include:


  • Ability to consolidate several storage areas
  • Minimal travel required for item retrieval
  • Improvements to stock rotation and throughput
  • Quick access to pick faces for streamlined order fulfillment


How to Operate a Pallet Flow Rack


A pallet flow rack has wheels, rollers, or flow rails set on a slope. The wheel or roller type varies based on the application and pallet dimensions. The highest part of the rack is at the load end, also known as the charge end, angling down to the unload or discharge end. When a forklift operator places the pallet on the load end, gravity and the sloped rack gently move the pallet toward the unload end. The operator places pallets of the same SKU into the lane until it is full.


For unloading, the operator goes into the opposite aisle and will take the first pallet at the unload end. When this pallet is removed, the pallets behind it will index forward, so a new pallet is in the pick position. Pallet flow supports FIFO inventory management since the first pallet loaded is the first pallet unloaded.


Practical Applications for Pallet Flow Systems


Pallet flow racks deliver maximum high density and selectivity solutions. It can be combined with other systems already in place to create integrated warehouse applications across multiple industry segments. A warehouse can integrate pallet flow racking into other pallet or case rack types or a multi-level pick module. Pallet flow can also be a standalone system.


Pallet flow racks are ideal for:


  • FIFO inventory management: Loading and picking are done from opposite sides for FIFO inventory retrieval.
  • Limited SKUs: Pallet flow is designed for a large array of pick faces with a limited number of SKUs. This racking is also ideal for applications that have several pallets of the same product.


Pallet flow racking is available in:


  • Structural or Roll-formed steel
  • GEN2 for facilities in zones of high seismic activity.
  • Galvanized steel, which meets requirements for the food and beverage and agriculture industries.
  • Single-wide configurations or double-wide configurations for operations handling two pallets at a time.


Benefits of Pallet Flow Systems


The pallet flow racking system offers many advantages, including:


  • Increased productivity: Pallet flow racking increases pick productivity. Since pallets move down to the picking position, forklifts reduce travel to retrieve a load. Forklifts will also have less travel time between aisles. Single/double and double forklifts can help warehouses see a 50% increase in productivity.
  • High-density storage: Pallet flow racking can store pallets between two and 20 deep. Compared to conventional pallet rack storage, pallet flow systems can double the storage capacity.
  • Quick pallet retrieval: Gravity replenishes the product picking position, making pallet retrieval faster while eliminating honeycombing.
  • Small footprint: The minimized footprint allows for a high volume capacity.
  • Reduced labor costs: A pallet flow racking system saves labor costs by up to 75%.
Gravity Pallet Flow Storage Solution

Maximize storage density in your warehouse or distribution center with Pallet Flow.

Other Racking Solutions

Contact Us to Learn More About Pallet Flow Racking Systems


Pallet Flow racking storage by Twinlode Automation improves storage capacity and streamlines high-volume operations. We have more than 40 years of experience installing pallet flow solutions. We also offer professional services for design, consultation, and implementation.