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What is Carton Flow?

Carton flow racks, or gravity flow racks, are a case storage method that uses wheels or rollers to convey cases from one end of a rack or shelving module to the other. In one storage bay you can create multiple levels of carton flow and each level will have a number of lanes of product, thus giving many more pick faces when compared to standard warehouse racking or shelving. Having more pick faces in a smaller area reduces pick paths and increases picking efficiencies. As well, when a case is removed, the remaining cases roll forward to the front – pickers do not have to reach into the racking and First-In First-Out (FIFO) is maintained.

carton flow racks

Who Uses Carton Flow?

Any operation where orders are picked in either full or split cases is a potential carton flow rack application. In general, fast moving products are picked directly from pallets, and very slow-moving products belong in storage systems like static shelving. Carton flow is suited to the middle range of product movement. As a rule of thumb, products that are suitable for carton flow are picked at least once a week, but not more than a half pallet worth of cases in that same week.

What Style of Carton Flow Do I Use?

The type of carton flow applied will depend on many factors – case sizes, case weights, the operating environment and product movement are just a few. 3D’s full width welded steel carton flow beds are best suited to heavy weight, high throughput operations with boxes at least 6” x 6” in size. Typical users of our product include food and beverage distributors, meat packing plants, and automotive part suppliers.

carton flow rack diagram
carton flow rack graphic

Features & Benefits

Cox Industrial equipment offers heavy-duty carton flow beds that provide the ultimate in abuse resistance and flexibility. 

carton flow rack side view
carton flow rack system

With a full deck of wheels (either steel or plastic) there is no need to re-profile when box sizes change. An impressive overall load rating of 50 pounds per square foot capacity is ideal for heavy cartons – beverages, canned goods, hardware, etc. With made-to-order width and lengths, 3D Storage Systems can provide beds to fit new installations or retrofit into existing pallet rack or carton flow systems.

‘Bed’ design allows flexibility in box size and weight and still provides the ability to maximize the use of the entire shelf. No “fixed roller width”, all wheels roll independently allowing infinite flexibility and superior carton flow to the pick aisle.

  • Both plastic and steel wheels are available to suit any load requirement.

    • Plastic wheels typically range to 35 lbs. per sq. foot.

    • Steel wheels allow weight ranges up to 50 lbs. per sq. foot.

  • Steel shafts that run the width of the bed give the system added impact resistance and weight capacity.

  • Welded one-piece bed frame with a durable powder coated finish

  • We can add impact plates and tilt shelves for greater carton access

  • Optional snap-in wire dividers allow for product separation while maintaining flexibility in width. Dividers can adjust with just one hand and can snap in virtually anywhere on the bed.

  • Beds are available with a variety of mounting styles, for use with step, channel or angle beams.

Let us show you how the features and benefits of our carton flow systems can be put to work for you. 

Call for details 314-567-4800 or Email Us

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