Full-Width Steel Roller Carton Flow

Carton flow is typically installed on lower pallet rack levels where employees can easily pick boxes and cases, while full pallets are stored above for replenishment. Lighter cartons may work with standard flow systems, while heavier cases require stronger rollers and tracks. The basic concept remains the same: instead of making employees reach into the back of a deep rack, gravity brings the inventory to them.

Cart-Trak Carton Flow Rack | Carton Flow Rollers: Cart-Trak carton flow brings the carton to the picker instead of making the picker reach for the carton. That improves picking efficiency, but just as important, it reduces the repetitive reaching and bending associated with retrieving boxes from the back of a shelf.

Cart-Trak tracks drop onto compatible existing pallet rack beams, turning a static beam level into a dynamic picking system without replacing the rack. Full-width rollers support cartons across the lane and can handle boxes of different shapes, sizes, and weights. Tracks are commonly available in 6″, 9″, 12″, and 16″ widths with roller spacing selected around the product. Smaller boxes may require tighter 1″ spacing, while larger cartons may work well with 3″ spacing.

End stops keep cartons from rolling beyond the picking face, and label holders help identify the SKU assigned to each lane. The rear of the system is elevated above the front to create the pitch needed for gravity flow. Load from the rear for FIFO inventory rotation or, where the operation calls for it, load and pick from the front.

A Carton Flow Cell with Span Track Lanes gives you the rack and flow components together in one freestanding system. Instead of retrofitting existing pallet rack, you can create a dedicated carton flow work cell for order picking, production, assembly, or other high-volume operations.

Span-Track uses full-width rollers arranged into defined flow lanes. Compared with staggered plastic wheel beds, the lanes provide a more defined location for each SKU and can be a more economical solution when carton sizes remain relatively consistent. The tracks span between the front and rear beams, keeping the system simple while providing durable gravity flow for boxes, cases, cartons, and totes.

Span Track Carton Flow Rollers are a good choice when you’re flowing larger, heavier boxes, cases, crates, and totes. The rollers provide continuous support across the carton and are designed to handle the impacts that come with busy picking operations. Employees are going to drop boxes onto carton flow. You might as well install a system designed to take it.

Another advantage is installation. Span-Track can be designed to drop over the front and rear beams of compatible existing pallet rack. The rack structure supports the tracks, eliminating the need for conventional shelving or intermediate supports in many configurations. Tracks can also be relocated when SKU locations change.

Full-width rollers can be particularly attractive compared with lighter plastic-wheel systems when durability and maintenance are priorities. Individual plastic wheels can eventually become damaged or require replacement. A properly selected roller track provides a simpler, heavy-duty flow surface designed for years of repeated picking.

If you’re handling heavier boxes and cartons, don’t automatically buy the least expensive carton flow system. The real cost isn’t just what you pay for the tracks. It’s what you spend repairing them, replacing components, clearing jams, and dealing with poor flow after the system goes into service. Sometimes buying the heavier-duty system once is cheaper than buying the lighter-duty system twice.

Full-Width Steel Roller Carton Flow FAQ

When should I choose full-width rollers instead of plastic wheel carton flow?

Start with the carton. Full-width rollers are a good choice for larger or heavier boxes, cases, crates, and totes that benefit from continuous support across the bottom. Plastic wheel systems can work very well for lighter cartons and applications requiring more flexibility across the shelf. Weight, carton dimensions, bottom construction, SKU variety, and required capacity should determine the system.

How do I determine the correct roller spacing?

The smaller the carton, the more support it generally needs. Smaller boxes may require rollers spaced approximately 1″ on center, while larger cartons may flow properly with wider 3″ spacing. Wider spacing can reduce system cost, but don’t save money by spacing the rollers so far apart that the carton doesn’t flow reliably. Provide the carton dimensions, weight, and bottom configuration when designing the system.

Can full-width roller carton flow be added to existing pallet rack?

In many cases, yes. Drop-in Span-Track and Cart-Trak systems can be designed to span between compatible front and rear pallet rack beams. Before ordering, verify the rack manufacturer and style, beam type, clear opening, rack depth, beam capacity, desired pitch, carton dimensions, and product weight. Existing rack should also be inspected to make sure it is suitable for the new application.