Convert Pallet Rack to High-Density Pick Slots with Carton Flow Rack

Fast, Accurate Order Picking is in Reach with Retro-Fit Carton Flow Rack

Are you finding that your fulfillment needs have changed from large orders to retail establishments or DCs to smaller, more individualized customer orders? Or perhaps the volume of SKUs your storage racking was designed to accommodate has multiplied like gremlins in a rainstorm? Maintaining a fast, cost-effective, orderly pick zone is a challenge if you don’t have the right tools —carton flow rack is an essential part of that tool kit.

Recent Survey Statistics

• 46% of DCs fulfill a mix of full pallet, cases, split-case, and individual items
• 18.5% increase in SKU volume cited by the average warehouse & fulfillment centers

6 Key Carton Flow Features Help Tackle Your Order Picking Challenges

1. 1. Existing low-level pallet rack converts into carton flow.
   2. Increase pick slots and SKUs by as much as 50% over static wire rack
   3. Shelf height is fully customizable to fit a variety of products
   4. Reserve products are stored right in the lane
   5. FIFO rotation – Automatic pick face replenishment
   6. Ergonomic & Accurate

Repurpose & Convert Existing Pallet Rack

Converting existing racking to carton flow is easily accomplished without purchasing new racking. Wheel or roller style conveyors can easily retrofit existing racks with provided brackets. Brackets can be designed with built-in stops and trays for loading or unloading. 

Once installed, the entire shelf becomes totally adaptable to any size container, tote, or box without the restraint of dedicated lanes based on size. Advantages include increased SKUs in the existing footprint, FIFO rotation, and increased picking efficiency.

Retro-Fit Carton Flow Rack

• Rail spacing is fully customizable to fit your inventory size and weight specs  
• Polypropylene wheels are durable and wash-down compatible if needed
• End-stops are adjustable and compatible with step beam design
• Optional lane dividers ensure SKUs are kept separate for regulatory compliance and pick accuracy

Give New Life to Your Old Pallet Racking

Converting your lower levels of pallet storage rack into a pick area allows you to keep your buffer stock right in the same racking system for quick replenishment and minimal labor expended fetching pallets. 

The carton flow rails fit into the rack on a slight incline to allow gravity to flow the inventory from the back or “charge” side of the system down to the pick aisle. This system design ensures that your order pickers are free to access the system from the front without forklift traffic in the aisle minimizing the risk of worker injuries. 

The rear of the system requires both forklift access to store and remove full pallets and manual labor to break down cases and load the flow rack. You can coordinate this activity with shift work to maintain a congestion-free zone.

Heavy-Duty Conveyor Installed in Racking

Heavy-duty roller conveyor is adaptable for applications when totes and cartons are stacked and very heavy. Roller conveyor can be designed to drop into existing racks and include guide rails to keep totes separated. This design guarantees first-in-first-out storage of raw materials and finished goods for quality control purposes. Conveyor is available in galvanized roller and frame design for long-term aesthetics preventing rust and tarnishing. The efficiency of roller conveyor on bottom levels allows pallet storage above to maximize the footprint of your warehouse, DC, or fulfillment center.

Heavy-Duty Carton Flow Rack

All Your Carton Flow Rack Products from a Local Trusted Source

Sometimes it’s hard to see how making a relatively modest change can really improve your operations. We assure you, it can. Carton flow rack most often falls into the “work smarter, not harder” adages. The Warehouse Optimizers, Inc. team can do an unbiased assessment for you to see if this type of conversion would work to your benefit or not.

Our team members are experienced listeners who can understand your workflow challenges and develop a plan that will meet your unique goals. When you rely on WOI, you receive turn-key support from concept to design and installation, including electrical and mechanical. 

What Sets WOI Apart?

Professional Installation – WOI installers are full-time, experienced material handling installation experts dedicated to workplace safety. Our project managers are OSHA-10 certified, and our team is fully licensed, insured… and very busy with, on average, 300+ jobs per year.

Total Customer Satisfaction – We are also committed to project excellence and 100% Customer Satisfaction.

The WOI 5-Step Total Satisfaction Experience™ guarantees that we will:

1. 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 today to speak with an WOI representative (865) 540-4004  or email at info@warehouseoptimizers.com. We proudly serve customers throughout the Southeast, including KENTUCKY, TENNESSEE, NORTH CAROLINA, ALABAMA, AND FLORIDA.