Gravity Flow Storage – Ideal First-in, First-Out Inventory Management Tool

Gravity flow storage is a fixture of warehouses and distribution centers for its ease of use, low maintenance, and cost-effective inventory storage and handling applications. It delivers productive, automatic stock rotation for large and small First-in/First-out (FIFO) inventory, all while saving valuable space in your facility.

FIFO describes a method of inventory management in which the first items to enter your warehouse are the first to leave, in an effort to avoid needless movement and spoilage of perishable goods, as well as effectively utilize space in your facility.

Gravity Flow Storage Solutions for Effective FIFO Inventory Management

There are two primary types of gravity flow storage systems, each of which has its own benefits and their own special applications that cross a multitude of industry sectors.

Carton Flow Rack

1. Carton Flow Rack System – Carton flow helps optimize your rack space for small items and full or broken-case picking. It is also useful for tote storage and kitting applications. Carton flow is designed to maximize pick locations in a consolidated area to decrease worker travel time while increasing pick rates. Each SKU is stored in designated lanes with automatically replenished reserve stock to not only keep the pick face filled but to keep the SKUs organized and ensure order picking accuracy.

Cartons are loaded in the rear (charge-side) of the rack system and flow to the opposite aisle for picking, providing a constant rotation of goods, and minimizing congestion in the pick aisle. This is ideal for quick turnover and ensuring products are being properly rotated out. Carton flow is installed in the pallet rack on specially designed mounts that allow the necessary lane pitch for the product to flow unimpeded. Carton flow rack is available in wheeled or roller style enabling the system to be custom-fitted to the inventory specs for best performance.

2. Pallet Flow Racking Systems – Pallet flow racking systems offer the same space-saving benefits and inventory flow benefits as carton flow, but for full pallet storage. Pallet flow is ideal for high-volume case-picking, or full pallet in & out applications. Pallets are loaded from a rear aisle and flow down to the opposite pick-face position. Pallet flow lanes are carefully configured using pallet and inventory specs, plus inventory load weights to ensure that they flow in a safe and reliable manner. Pallet flow systems are typically 2-10 pallets deep but can be designed for very deep lanes of 20+. Features such as speed controllers and pallet separators may be necessary to ensure the most productive and safe use of your pallet flow system. Various pallet styles can be accommodated including Orbis automotive pallets, wood pallets, and custom Ropak style containers.

Pallet Flow Rack

3. Wait, did we say there were two major applications of gravity conveyor rack? A third option is to use both carton flow and pallet flow in a consolidated pick area called a pick module. Pick Modules combine rack systems into a mezzanine-style fulfillment operation.   The combination of efficient small item and carton picking from carton flow set in the lower section of the system is benefited with constant replenishment from full pallet reserve storage. Take-away conveyor can also be positioned in the pick aisle for fast order fulfillment as SKUs are picked or orders are compiled. 

Gravity conveyor systems are either equipped with wheels, rollers, or chutes, depending on their intended use, and can be used in a multitude of applications from mobile carts, stand-a-lone, reserve storage, case picking, layer picking, pallet building, and more. Specific FIFO benefits include:

• Easy to use and productive for fast, high-volume turn-over
• Minimizes warehouse travel and pick area congestion
• Gravity powered — meaning zero reliance on electricity, batteries, and digital interface
• Highly configurable for integration into any warehouse design and spatial parameters
• Cost-effective storage and minimal upkeep
• Minimal maintenance requirements

When You’re Ready to Consider Gravity Flow Systems

The team at Storage Solutions Inc.(WOI) is ready to help you find the gravity flow solution that best suits your warehousing needs. For a full list of the conveyor systems we offer, click here. With our 5-Step Total Satisfaction Experience™ you are guaranteed that we listen and execute your project paying special attention to your particular application, project timelines, safety, and appearance of the finished product. Contact a member of our team today and chat, Zoom, or call us for a prompt response. We proudly serve customers in Tennessee, Alabama, and throughout the Southeast.