What Are Flow Racks, and Do You Need Them in Your Facility?

A carton flow rack is a first-in, first-out (FIFO) storage system that utilizes gravity flow to move boxes (or totes, or bins, or other receptacles) forward towards the front of the rack.

Most flow rack systems consist of a series of slightly inclined flow rails (or lanes), with or without rollers (in which case they're considered roller racks), which display SKUs. As the oldest cartons are picked, the newer SKUs slide forward down the rails or inclined roller tracks. This simple design provides semi-automated inventory rotation, ideal for maximizing warehouse space use — and optimizing the picking process.  

So, should you consider gravity flow rack systems for your facility? Below, we’ll discuss the advantages of carton flow racking systems and provide some considerations to keep in mind when purchasing.

Carton Flow Racks: Applications and Benefits

Gravity flow racks are ideal for situations in which SKUs are roughly uniform in product size. The design of the flow-through rack might mitigate this somewhat, but in general, it’s best to use a carton flow system when the SKU size will remain relatively constant (even if products aren't technically cartons). While pallet flow racks certainly exist, this design is less common in pallet racking than in carton storage.      

If your facility stores products that are turned over on a regular basis, FIFO racking can help you manage order picking (and limit storage sprawl). These space-saving storage solutions are ideal for:

• Warehousing and Order Fulfillment - Gravity flow systems increase storage density and space optimization, reducing handling times and operational costs over time.
• Manufacturing - Flow racks can seamlessly integrate into manufacturing assembly lines to optimize key product feeds and tasks.
• Foods and Beverages - Food-safe flow racks minimize handling and reduce waste via FIFO.
• Pharmaceuticals - Secure flow racks can protect products while simplifying inventory tracking and management.
• Automotive Parts - Heavy-duty flow rack systems efficiently deliver loads of virtually any weight or size, which makes them ideal for automotive batteries and similar parts.
• Electronics Storage - Carton flow racks can provide FIFO management while limiting the potential for electrostatic damage (ESD) by minimizing handling.

Both pallet flow racking and smaller carton flow racking systems are particularly valuable in retail warehouses or distribution centers. They improve order picking speed in high-volume picking operations, improving throughput and fulfillment times considerably.  

Essentially, flow racking systems serve as excellent ergonomic solutions wherever order picking is a pain point, and it’s an inexpensive upgrade for static storage. With that said, it’s not an ideal approach for operations that routinely store multiple non-uniform SKUs on the same warehouse racks, with or without roller conveyors — though again, this depends on the design of the rack unit.

Choosing Flow Racks for Order Picking and Fulfillment

When implementing a FIFO system, you’ll need to consider the weight and physical size of SKUs and procedures for loading and unloading. You should also consider the design of the racking system itself: The load capacity, footprint, and durability of the unit can be crucial in determining your return on investment.

Solus Group carries the BHS Flow Through Rack (FTR), which is designed to enhance fulfillment while providing years of durable service. These mobile carton flow racks provide: 

• Efficient Inventory Management: Inclined shelves and secure rails automate stock rotation, reducing waste and improving workflow.
• Durable and Mobile Design: The steel construction with a powder-coated finish offers high weight capacity (up to 4,000 lbs) and acid resistance. Phenolic casters allow for easy movement without damaging floors.
• Space-Saving and Versatile: The compact design fits under existing pallet racks, maximizing storage density. Lockable brakes keep the unit secure, while its clean design makes it suitable for both showroom displays and work areas.
• Easy to Maintain and Use: Arrives fully assembled and requires minimal maintenance.

We also carry the Automotive Battery Rack (BS-ABR), a heavy-duty flow rack designed to handle battery stock. Designed to handle up to 96 batteries, the BS-ABR features acid-resistant paint and side rails to protect products during travel. 

Custom Flow Racks for FIFO Order Fulfillment

Custom flow shelving units are available to meet the unique needs of any facility. By customizing your equipment, you can efficiently feed order picking lines, handle SKUs of different sizes with a single racking unit, or build a true omnichannel fulfillment operation.

Learn more about shelving & racking solutions from Solus Group. To explore custom solutions, call 314-696-0200 today to speak with a member of our sales team.