Gravity Flow Rack in Warehouses

Gravity flow racks are a highly efficient storage solution used in warehouses to improve order picking and inventory rotation. These systems work using sloped roller tracks that allow product to flow from the loading side (also called the charge side) to the picking side (or discharge side) using gravity. This setup supports a First-In/First-Out (FIFO) inventory method, ensuring older inventory is picked before newer stock. Gravity flow racks are especially popular in high-turnover warehouse environments such as distribution centers and manufacturing facilities.

Carton flow racks are one of the most common types of gravity flow systems. These typically integrate Span-Track or Cart-Trak full-width aluminum roller lanes into standard pallet rack frames. Carton flow systems are ideal for lightweight cartons or small boxes, offering high-density storage and improved visibility for pickers. These racks are positioned in the lower levels of pallet rack systems to create ergonomic picking aisles, while full pallet storage is often maintained on the upper levels for easy replenishment.

For heavier items, case flow systems are a more robust option. These systems utilize heavy-duty Dyna-Flow staggered poly plastic wheel beds or heavy-duty steel rollers that can accommodate bulkier, heavier cartons and cases. In deep-lane case flow setups, pallet flow rails with brakes are often used to control product speed and prevent damage. This type of system is ideal for operations where cartons are larger or heavier, such as automotive parts or food and beverage distribution.

Heavy-duty pallet flow rack systems take gravity flow to the next level by allowing full pallet loads to move along deep-lane flow rails. These systems are engineered to support and guide heavy pallets and are equipped with speed controllers and brakes to ensure safe, controlled flow. Pallet flow racks maximize storage density and throughput, making them ideal for high-volume inventory in cold storage, grocery warehouses, or manufacturing environments.

To ensure smooth and consistent product movement, flow lanes are made with high-quality components such as aluminum or galvanized rollers. These materials resist corrosion and wear, ensuring long-term reliability. By organizing pick faces at lower levels and storing reserve inventory above, gravity flow racks create a highly organized and efficient warehouse layout. This reduces travel time for pickers and increases overall productivity while maintaining an orderly, FIFO-friendly system.