Carton Flow Rack Ordering Made Easy – Follow These Steps!

Customize Your Wheel Style Flow Rack Design with These Tips

Carton flow rack is a great way to arrange and consolidate cases, cartons, and totes for more efficient order picking. Carton flow is available in roller or wheeled rails that mount within regular racking at a slight pitch that flows inventory from a load aisle to an opposite pick aisle. The flow rack levels create a concentrated, ergonomic storage solution to boost pick rates and putaway tasks. Carton flow rack is best suited for high-volume, medium-turn rate inventory. 

How Does Carton Flow Rack Benefit Your Order Picking? 

• Consolidates SKUs into an optimized pick zone
• Supports concurrent, safe activity for putaway and picking
• Increases pick accuracy
• Lowers equipment & worker travel costs
• Saves valuable warehouse space
• Creates additional SKUs to existing footprint

The benefits of carton flow rack are easy to see, but selecting the proper configuration and design can be a bit more complex. 

To help, we’ve compiled a list of the most common errors made when ordering carton flow rack. Reviewing these mistakes will give you a better understanding of system design and lead you to avoid costly headaches.

1. Carton Flow Is Not A One-Size-Fits-All Product

This is the #1 mistake. Your choice of carton flow product centers around whether your inventory specs are consistent or vary. Roller products support uniform-size cartons most efficiently, while wheeled beds allow differently-sized SKU lanes within the same level. Once you establish your carton consistency, it’s time to narrow your selection of products further based on load weight and lane depth.

It’s also important to consider future inventory needs when ordering carton flow rack. The good news is that carton flow rack is adaptable to changes with good design.

2. Confirm Your Warehouse Software is Compatible

All warehouse order-picking software is not created equal. Picking software such as pick-to-voice and pick-to-light systems may require accommodations for labels or automation features affixed to the beam. It is best to provide your system designer with all the specs regarding your order-picking software to avoid potential issues.

3. Ordering Carton Flow Rack Without Performing A Current SKU Analysis 

An ideal carton flow system layout is planned around your inventory information, including SKU volume, number of SKUs, and batching/sorting methods. Using the appropriate data, you can optimize the system and create an ergonomic, efficient, and accurate zone-picking solution for your fastest, medium-turn, and slower-moving SKUs. 

4.  Accessorize Your Carton Flow

Custom-fit accessories enhance putaway and picking accuracy and productivity, increasing profitability. Here are some available options.

• Lane dividers – Choose partial or full-length lane dividers to provide a physical barrier between SKU lanes. Lane dividers are easy to install and reposition for reprofiling.
• Entry guides – snap into position on the charge side of the system and help workers more quickly and accurately load inventory into the SKU lanes. 
• Steel impact trays – mount at the charge side to place heavy cartons and totes in the SKU lanes without damaging the wheels or roller tracks. Inventory is easily slid from the tray into the lane to flow to the pick aisle.
• Angled trays – add a tiltable tray to the pick-side of your carton flow lane to provide better product visibility and more ergonomic positioning for your workers. They are easy to install, customize, and adjust the tilt as needed.

Carton Flow with Impact Tray and Full-Length Lane Dividers

5. Choosing Incorrect Carton Flow Mounting Brackets

Mounting carton flow rails to new or existing crossbeams requires brackets with the right height, pitch, and mounting interface. Work with an experienced team like WOI to ensure you get the best fit to provide the most efficient function of your flow rack.

6. Ordering A Carton Flow System Without Testing It First

It is a good idea to test a shelf level before your purchase to confirm proper flow and pitch. Call WOI to order a test lane and give it a try in your facility prior to finalizing your order. We also offer experienced, professional racking installation services to ensure your system functions optimally. 

Advanced Planning & Expert Advice Deliver the Greatest ROI

On the plus side, there are many carton flow options to customize your solution; on the other side, it can be a bit confusing to create the most cost-effective design. Our warehousing solutions experts are up for the challenge and will work with you to create a system that meets your specific needs to get the most value from your system.

The team at WOI comprises over 180 years of material handling experience — all dedicated to meeting your warehousing needs. As opposed to selling product lines, we solve customer challenges. Our team is also committed to delivering 100% Customer Satisfaction with every application as we abide by our Total Satisfaction Experience™ (TSE) tenets. 

The Total Satisfaction Experience focuses on five essential customer experiences:

1.     We will listen to your needs
2.     Execute your project with particular attention to your unique application
3.     Stick to project timelines
4.     Ensure a safe environment
5.     Pay close attention to the detail of the finished product

A strong focus of our TSE commitment involves the project installation. Our team follows strict protocols and ensures the finished product meets customer expectations.

WOI Installation Team:

• Industry Experienced Professionals
• OSHA Trained & Certified
• Certified Drug-Free Workplace
• Licensed General Contractor
• Job Safety Analysis
• Forklift, Scissor Lift, and Aerial Lift Operator Trained

Our installation team is available for demolition and re-installation of existing systems.  Transportation to and from facilities can be included along with permitting if necessary.

Call WOI today for a free consultation and schedule a site inspection —dial (833) 336-7005 or email info@warehouseoptimizers.com. 

WOI proudly serves customers throughout the Southeast, including KENTUCKY, TENNESSEE, NORTH CAROLINA, GEORGIA, ALABAMA, AND FLORIDA.