Pallet Flow Racking System

Pallet Flow Racking System

Pallet Flow Racking is another form of dense storage system to utilize maximum ‘Storage Cube’. As the name depicts, Pallet flow from one end to another end by gravity force on metal rollers. Hence by default, this system operates on FIFO (First In First Out).

This system is designed to store pallets of multiple high and multiple deep. Each level shall be dedicated to one type of SKU only. This racking is suitable for batch production / storing homogeneous products and expiry date for SKU is critical.

Pallet flow racking system: agile operations and perfect FIFO turnover
Pallet flow racking consists of high-density storage structures formed by slightly sloped channels with rollers that enable pallets to slide into place. Palletized loads are inserted in the highest part of the channel and move by gravity to the opposite end, where they are ready to be removed.
There are no intermediate aisles in a flow rack system, which increases storage capacity. In addition, the flow through racking can work in line with the FIFO (first in, first out) strategy, facilitating efficient inventory management.

ADVANTAGES OF PALLET FLOW RACKING

  • Maximum utilisation of surface area: pallet flow racking is a high-density storage solution that significantly increases a warehouse’s capacity.
  • Flawless product turnover: its compatibility with the FIFO method fosters excellent inventory control.
  • Time savings: having all SKUs available in a single working aisle makes it easy to locate any product, reducing forklift manoeuvring time and speeding up pallet removal.
  • Separation of loading and unloading: pallet storage and retrieval are performed from separate aisles. This eliminates interference and enables forklifts to work without interruptions.
  • Multiple SKUs: although each channel houses a single SKU, these can vary between the different channels.
  • Better energy consumption: implementation of this system in facilities run at low temperatures reduces energy consumption since the volume to be cooled is smaller.
  • Safety and reliability: the different elements that make up Mecalux’s pallet flow racks are designed to ensure risk-free operation for operators and goods.

HOW DOES A PALLET FLOW RACKING SYSTEM WORK?

Perfect stock control with minimal movements

Gravity flow racks are characterised by their extremely simple operation. Their structural configuration fosters remarkably agile management that shortens manoeuvring times and reduces the distances travelled by forklifts. The result? Fast storage and retrieval operations.

Pallet storage

The forklift places the pallet at the channel entrance on the higher side of the racking. The pallet is usually inserted with its deckboards perpendicular to the rollers.

Pallet movement
The pallet moves inside the channel by gravity, sliding autonomously over the rollers until reaching the end (a retainer or the previously stored pallet).

Pallet removal
The forklift picks up the pallets in the unloading aisle on the other side of the racking. When the first pallet is removed, the remaining pallets in the channel move forward one position.

With 2 working aisles (FIFO method)

This is the traditional configuration. The pallet is loaded on the rollers in the input aisle and slides by gravity to the output side, where the unloading aisle is located. Thus, the first pallet in is the first out.

PALLET FLOW RACKING CONFIGURATIONS

Highly versatile storage solution adaptable to diverse needs
Gravity racking systems can be configured in several ways. This depends on the required goods management method and the type of operations to be performed, e.g., order picking from the racks themselves.

With a single working aisle (LIFO method)

Equivalent to a push-back pallet racking system. The goods are loaded and unloaded from the same aisle. The first pallet is placed in the first location of each channel. Using a forklift, the second pallet is inserted, pushing the first pallet forward and occupying its position. Thus, the first pallet in is the last to be retrieved.

Flow channels for picking from pallets

Levels of pallet flow racking are sloped at one angle to feed the pick stations, which are also pallet flow racks but sloped at the opposite angle. The pallets from the upper levels are inserted into the lower levels for picking. The reserve channels also occupy the upper part of the picking aisle.

Pick modules with pallet flow rack channels

Pallet pick stations are set up on several floors, supplied with goods coming from the reserve pallet flow rack channels. Each floor can be assigned to a different type of product or turnover. The operator places the goods on a trolley, pallet truck or automatic conveyor.

Automated storage systems with pallet flow racking

Pallet flow racks can be served by fully automatic stacker cranes. It is possible to incorporate two stacker cranes, automating both storage and retrieval from the racking. Alternatively, one machine can be installed (e.g., in the loading aisle, with pallet removals carried out by forklifts).

Clad-rack warehouses with pallet flow racking

As with all other pallet racking systems, pallet flow racking can constitute the structure of a clad-rack warehouse. In addition to the stored loads, the racks support the building’s roof and purlins to which the cladding panels are fixed.

PALLET FLOW RACKING COMPONENTS

The manufacturing quality of the different components used in Mecalux’s pallet flow racking makes the system highly reliable, ensuring the correct operation of the system and a long service life.

ROLLERS

Made of electrowelded steel, these enable the pallets to slide smoothly through the channel. Their spacing and diameter will vary according to the type and weight of the pallet.

FRAMES

Vertical elements consisting of two vertical profiles (uprights) joined together by means of cross-ties and diagonals.

FLOW RACK BEAMS

Horizontal elements that support the roller tracks along which the pallets stored in the racking slide.

EXIT BEAMS

Beams located at the end of each channel and into which the flow rack channel’s profiles are fitted. They incorporate retaining stops.

END STOPS

These replace the exit beam when the channel protrudes past the supporting beam.

BRAKE ROLLERS

They control the speed at which the pallets move and act directly on them according to the force generated. The greater the speed or weight of the pallet, the greater the braking force.

BRAKE DRUM

They perform the same function as the brake rollers, acting on two adjacent rollers or directly on the pallets themselves. Brake drums are used when it is not possible to fit brake rollers.

PALLET CENTRALISERS

These center the pallet at the entrance to the channel. Their purpose is to prevent the pallet inserted from diverging from its path.

SAFE LOAD WARNING NOTICES

These contain the technical racking information as well as the label indicating the deadline for the next inspection. These notices are placed in easily visible areas at the ends of the racking system.

GRAVITY RACKING ACCESSORIES

Set of elements used to adapt the system to specific needs.

PALLET RETAINERS

These parts old pallets back or separate them, making it easier to retrieve the first pallet and distribute the pressure exerted between them. Their installation is optional and depends on the features of the system.

CHANNELS AT FLOOR-LEVEL FOR PALLET TRUCKS

These combine long rollers with sets of short rollers to operate with pallet trucks or stackers. They are very common in production and dispatch areas.

 

Flow racking systems consist of very particular types of high-density racks: their components and structure leverage gravity to streamline all goods extraction and storage operations. They’re also known as gravity flow systems.

Security systems

Without some kind of control mechanism in place, the force of gravity acting on heavy loads can be problematic. That’s why pallet flow racks are equipped with the following elements to ensure safe load handling:

  • Brake rollers: slow down the speed of the load depending on the force generated. The faster the acceleration, the greater the brake force.
  • Pallet centralizers: assist with pallet entries to ensure they fit perfectly in the channel.
  • Ramp stops at the ends of the channels: reinforce this area to prevent it from giving way to the accumulated weight of the goods at the exit point.