Pallet Flow Rack Or Carton Flow Rack? Understand the difference between the two and which one to choose?

Gravity Flow Rack which is familiar work in the logistics industry for bulk storage and picking module with a number of terms. However, some can cause confusion, either due to similarities in words or functions. In the case of carton flow or pallet flow, for live storage workflow, how to choose the right one?

Despite the similar names and the fact that both solutions work for transporting palletized loads, they are different. Below, we explain what a flow is and how it differs bewteen pallet flow and carton flow: 

What is a pallet flow rack?

A pallet flow rack is a gravity-fed storage system designed for full pallets of goods. It consists of inclined lanes equipped with rollers or wheels that allow pallets to flow from the loading end to the picking end using gravity. The system operates on a First-In, First-Out (FIFO) principle, making it ideal for inventory rotation.

Key Features of Pallet Flow Racks:

• Gravity-fed system: Pallets flow automatically from back to front
• FIFO inventory management: Ensures proper product rotation
• High-density storage: Maximizes storage capacity in available space
• Separate loading and picking aisles: Improves workflow efficiency
• Automatic product rotation: Reduces handling and labor costs

Best Applications for Pallet Flow Racks:

• Food and beverage storage with expiration dates
• Pharmaceuticals and medical supplies
• Cold storage and freezer applications
• High-volume distribution centers
• Products with varying sizes that need rotation
• Operations requiring automatic stock rotation

What is a carton flow rack?

A carton flow rack is a gravity-fed storage system designed for individual cases, cartons, bins, or totes. It features inclined shelves or roller tracks that allow smaller items to flow from the loading end to the picking end. This system is optimized for piece-picking operations and fast-moving consumer goods.

Key Features of Carton Flow Racks:

• Designed for smaller items: Handles cartons, bins, and totes
• Versatile shelving: Adjustable to accommodate different product sizes
• High picking rates: Optimized for fast individual item retrieval
• Compact design: Efficient use of vertical space
• Easy access: Items are always at the front for quick picking

Best Applications for Carton Flow Racks:

• E-commerce fulfillment centers
• Retail distribution operations
• Fast-moving consumer goods
• Electronics and small parts storage
• Order picking operations
• Facilities with high SKU variety

Which one to choose?

After clearing up the confusion between pallet flow and carton flow systems, it's time to understand when to choose each one. Contrary to what you might think, the right racking system isn't defined by your industry—it's defined by your specific application needs. The main factors that influence this decision are:

• Product Weight: For lightweight items (less than 50 pounds per carton), carton flow racks are the best option. When products exceed this weight and require pallet handling, the physical effort needed by workers becomes very high. Therefore, from full pallet weights onwards, pallet flow systems are more recommended.

• Storage Volume: Carton flow racks are only suitable for smaller, individual items. For medium-volume storage needs, a mixed approach with both systems works best, while for large-volume pallet operations, the best option is a dedicated pallet flow system.

• Picking Frequency: If the picking volume is high with many different products, it is recommended that carton flow racks be used. This method reduces the physical effort required by employees, contributing to better productivity in the work environment.

When Should You Choose Pallet Flow Rack:

• Your operation handles full pallets regularly
• Products have expiration dates requiring rotation
• You need high-density storage for bulk items
• Cold storage or freezer applications are involved
• Heavy, palletized goods make up most inventory

When Should You Choose Carton Flow Rack :

• Individual item or case picking is primary
• You handle fast-moving consumer goods
• E-commerce or retail fulfillment drives operations
• Product variety is high with smaller quantities
• Quick picking speed is essential

If you looking for reliable flow rack manufacturer, contact Heda shelves or click here to call experts in Whatsapp. We are leading factory in warehouse storage rack in China and has a specialized technical team dedicated to researching and planning the best solution using the best products.