Pallet Flow Rack

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  • High density storage
  • Meets FIFO requirements
  • For uniform sized packages and pallets
  • Can be operated with a reach truck and/or a counterbalanced forklift
  • Requires sturdy pallets or cartons

Loading: Pallet weights up to 3000lbs/1500kg


  • Uprights: Pre-galvanized or painted
  • Beams: Pre-galvanized or painted
  • Accessories: Pre-galvanized or painted

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Every end-product is precisely tailored to your specifications. We begin by gathering detailed measurements of your product; including length, depth and weight. Based on that information, we can custom-design pallet flow racks to ensure a perfect fit for your needs, ensuring a cost-effective and efficient storage solution.

Gravity Flow Pallet Rack

A Gravity Flow Pallet Rack, also known as a flow rack or carton flow rack, is a type of dynamic storage system designed for high-density storage and efficient stock rotation. It utilizes inclined shelves equipped with rollers or wheels, allowing products to glide smoothly from the loading end to the picking end under the force of gravity. This system is particularly well-suited for operations that require First-In, First-Out (FIFO) inventory management.  

Advantages of FIFO Pallet Flow System

First-In, First-Out (FIFO) Inventory Management:

Ensures the oldest stock is used first, which is necessary for managing perishable goods and items with expiration dates, helping to maintain product freshness and reduce waste.

High Storage Density:

Maximizes storage capacity by reducing aisle space, allowing more pallets to be stored in a given area compared to traditional static racking systems, optimizing the use of available warehouse space.

Improved Picking Efficiency:

Products are automatically fed to the picking face, minimizing the time and effort needed to locate and retrieve items, significantly speeding up the order picking process and enhancing throughput.

Reduced Labor Costs:

The automated flow of goods reduces the need for manual handling, lowering labor costs and increasing productivity by enabling workers to focus on other tasks.

Enhanced Safety:

By minimizing forklift traffic within the racking area, the system reduces the risk of accidents and improves overall workplace safety, creating a safer environment for warehouse staff.

Pallet Flow Racking System Warehouse Applications

Warehouse Application Description
Food and Beverage Warehouses Ideal for perishable goods, ensuring FIFO inventory management to maintain freshness.
Cold Storage Facilities Used in refrigerated and frozen environments for space efficiency and quick stock rotation.
Pharmaceutical Warehouses Essential for managing sensitive products with strict expiration dates and regulatory compliance.
Retail Distribution Centers Optimizes picking efficiency for a large variety of products with different turnover rates.
Consumer Goods Warehouses Suitable for fast-moving consumer goods (FMCG), enhancing order fulfillment speed and accuracy.
E-commerce Fulfillment Centers Supports high-volume operations, improving order picking and shipping processes.
Automotive Parts Warehouses Efficient for managing a wide range of parts and components, reducing downtime in production.
Manufacturing Facilities Supports just-in-time (JIT) inventory systems, ensuring efficient movement of raw materials.
Wholesale Distribution Centers Facilitates handling of bulk quantities of products, improving storage density and order processing.
Health and Beauty Product Warehouses Manages products with varying shelf lives, ensuring FIFO rotation for cosmetics and personal care.
Chemical and Hazardous Material Storage Ensures safe and efficient storage of chemicals and hazardous materials, with strict inventory control.
Electronics Warehouses Stores high-value, sensitive electronic components and products, ensuring quick access and minimal handling.
Packaging Material Storage Efficiently stores packaging materials and supplies for packing and shipping operations.
Medical Supplies Warehouses Manages critical medical supplies and equipment, ensuring timely access and proper stock rotation.

How High-Density Pallet Flow Rack Works

The Pallet Flow Racking System operates on the principle of gravity-fed flow lane movement. Pallets are loaded onto the flow rails system at the higher end, typically using a forklift or other storage solution. The system consists of rollers or wheels set at a slight incline, forming lanes that guide the pallets towards the lower end, known as the picking end.

Once a pallet is loaded onto the rollers, gravity takes over, causing the pallet to move smoothly and slowly down the inclined lanes towards the picking end of the rack. Each lane is typically equipped with lane dividers to separate the pallets and ensure they move independently.

At the picking end, workers can easily access the pallets for picking. As each pallet is removed, the next pallet in line gently rolls forward to the picking position. This continuous flow ensures that the oldest stock (first loaded) is always picked first, following the First-In, First-Out (FIFO) inventory management principle.

Meanwhile, at the loading end, as pallets are removed, new pallets can be loaded onto the rollers to replace them. This ongoing process of loading and picking ensures efficient stock rotation and maximizes storage density within the warehouse.

What Determines the Type of Wheel or Roller Used in a Pallet Flow rack?

Key considerations include load capacity to support pallet weight, material handling characteristics such as load type and shape, and the type of roller or wheel material. Factors such as the incline angle and desired flow rate influence the choice, as do friction characteristics and maintenance requirements. Environmental conditions, noise levels, and cost considerations also play a role in selecting the most suitable wheels or rollers for the specific application.

How It Compares to Other Pallet Rack Systems:

Selective Pallet Rack:

  • The most common type of racking system, offering direct access to each pallet. However, it requires more aisle space and is less space-efficient compared to gravity flow racks.
  • Ideal for operations with a lower turnover rate or where FIFO is not crucial.

Drive-In/Drive-Through Rack:

  • Provides high-density storage by allowing forklifts to drive directly into the rack structure. It is more space-efficient than selective racking but does not support FIFO.
  • Better suited for high-turnover, non-perishable goods where stock rotation is not a priority.

Push-Back Rack:

  • Uses a system of carts that move along inclined rails. Pallets are loaded from the front and pushed back, allowing for Last-In, First-Out (LIFO) inventory management.
  • Offers high density similar to gravity flow racks but is more suitable for applications where LIFO is acceptable.

Pallet Flow Rack:

  • Similar to gravity flow racks but designed specifically for pallets. It uses inclined rails with rollers for high-density, FIFO storage of pallets.
  • Often used interchangeably with the term “gravity flow rack” when referring to pallet storage.

What Do You Need to Know About Dynamic Storage Systems

Flow pallet racking is a high-density storage system for heavy duty cartons and pallet loads. Regular maintenance is necessary to ensure the smooth operation of Pallet Flow Racks. This includes inspecting rollers, loading/unloading aisles, wheels, and brakes for wear, checking the alignment of rollers, and ensuring the proper incline of the rack. Maintenance schedules should be established based on usage and environmental conditions.


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