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 to move boxes (or totes, or bins, or other receptacles) forward towards the front of the rack.

It consists of a series of slightly incline shelves (or lanes), which display SKUs; as the oldest cartons are picked, the newer SKUs slide forward. This simple design provides semi-automated inventory management, ideal for maximizing storage — and optimizing order picking. 

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

Carton Flow Racks: Applications and Benefits

Flow racking is ideal for situations in which products are roughly uniform in size and shape. The design of the flow-through rack might mitigate this somewhat, but in general, it’s best to use gravity racks when the SKU size will remain relatively constant. 

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). Carton flow racks are ideal for:

• Warehousing and Order Fulfillment - FIFO rack systems increase storage density and efficiency, reducing costs over time.
• Manufacturing - Flow racks can seamlessly integrate into manufacturing processes to streamline key 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.

Essentially, flow racking makes sense 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 shelving units — 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. You should also consider the design of the racking system itself: The 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. Flow Through 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.