5 Reasons Your Order Picking Operation Needs Carton Flow Rack Optimization

Carton Flow Rack Maximizes Space and Boosts Warehouse Efficiency

Carton Flow Rack is a gravity flow solution designed to enhance efficiency and accuracy in case and each picking operations. This storage solution, also referred to as “case flow” or “tote flow” rack, functions similarly to pallet flow rack. By utilizing distinct load and pick aisles and robust rollers or wheeled tracks, carton flow rack employs seamless first-in, first-out (FIFO) item selection. Integrating carton flow rack with other material handling systems is a breeze, and it can significantly increase the number of case pick locations, up to three times more than traditional pallet rack setups.

Advantages:

• Maximize space – Save up to 50% compared to static rack or shelving
• Add pick slots – Achieve up to 40 locations per bay
• Reduce labor costs – Save up to 50% in travel and pick time
• Significantly boost productivity – faster, more accurate picking
• Support ergonomic picker positioning – less bending and reaching 
• Facilitate FIFO inventory rotation – separate load and pick aisles

Now that we’ve explored the benefits let’s determine if it’s the ideal addition to your material handling storage system.

Sign #1

We’ve got floor and 1st level rack locations filled with full-case and partial-case picks with slow-moving SKUs.

Solution: Add carton flow to floor-level bays

By transitioning floor-level pallet rack positions into carton flow rack, you can unlock as many as 40 case pick locations per bay, surpassing the capacity of standard pallet rack configurations. This enhancement to your storage system enables you to effectively achieve your inventory goals while eliminating wasted space caused by partially filled pallets.

Sign #2

Our case pick rates need a real boost.

Solution: Carton flow reduces travel time and leads to higher picking efficiency

Experience a 75% reduction in travel time compared to selective pallet rack systems with the implementation of carton flow racking. This innovative solution optimizes case and each picking operations within a compact footprint, enhancing efficiency and accelerated order selection. 

Leveraging a gravity-fed design and employing the first-in, first-out (FIFO) inventory rotation method, carton flow racking positions cartons directly at the aisle face, ensuring improved visibility and effortless, ergonomic access. It also eliminates employee bending or straining to reach cartons stored on selective rack decking. 

Sign #3

Our product lines and SKUs are always changing, but our current space just doesn’t accommodate them.

Solution: Dyna-Flo full wheel bed shelves are your answer – They’re designed to accommodate changing carton shapes and sizes

This challenge is all too common, but carton flow provides a palpable solution to changing product lines and SKUs. For example, Dyna-Flo carton flow and Dyna-Deck replacement carton flow are both easy-to-install full-wheel bed options designed to handle any carton size you’ve got –see for yourself in this video example from Mallard Manufacturing.

Sign #4

Our inventory changes every season, and we need something to accommodate. 

Solution: Stand-alone mobile carton flow units are your new best friend. 

Carton flow systems offer an ideal standalone solution for managing temporary inventory fluctuations and handling seasonal fulfillment. With its user-friendly assembly and reconfiguration capabilities, this versatile storage solution can be adapted to suit your needs. Roll it out when you need it and stow it away when the temporary need has passed. Mobile carton flow is designed to provide optimal functionality, especially suited for low-ceiling spaces or mezzanine applications.

Sign #5

We’re committed to an environmental goal and our systems to being environmentally friendly. 

Solution: Maximize your space and efficiency and eliminate the need for ever-changing systems.

Carton flow racking operates solely on the power of gravity, making it an eco-friendly and energy-efficient storage solution that optimizes space and minimizes operating expenses. By implementing this, you can significantly reduce the number of material-handling vehicles required for order selection, resulting in additional energy savings and reduced equipment costs. This efficient system also allows for the release of wooden or plastic pallets, freeing them up for other purposes and effectively decreasing the overall quantity of pallets needed to support your inventory.

Go with the Flow –Call WOI for Expert Customer Service

If you’ve noticed any of these signs, don’t hesitate to reach out to our team of gravity flow experts. Discover how Storage Solutions Inc can revolutionize your space and streamline order-picking efficiency with carton flow. We also provide professional rack installation focusing on safety and minimal disruption.

Call to speak with your local WOI representative, and ask about our Total Satisfaction ExperienceTM.

The WOI 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

Call WOI today to source your new or used pallet racking system — dial (833) 336-7005 or email info@warehouseoptimizers.com.

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