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Different product groups require different picking or storage mode. In high density storage, Gravity Flow and Wheels Back is common self-moving racking system in industrial warehouse workflow. If you're still considering pallet flow racking or push back racking, this article is for you. There's a difference between these operation and application for warehouse or distribution centers.
Key Takeaways
Pallet flow and push back systems both aim to make warehouse storage more compact, efficient, and productive. The decision between them should be based on the nature of stored goods, throughput requirements, and how the facility uses its space. Each has trade-offs, and what works best depends on whether product rotation or storage density is the priority.
A pallet flow rack (also called gravity flow rack) uses slightly inclined channels equipped with rollers or wheels. Pallets are loaded from the “back” (loading side) and glide forward under gravity toward the “front” (picking side) as preceding pallets are removed.
This design makes pallet flow ideal for operations needing FIFO that the oldest goods are always retrieved first. It also reduces forklift travel because loading and unloading happen on separate, designated aisles.
Pallet flow rack is often chosen for high-volume, high-turnover environments, especially where inventory age, expiration, or shelf life is a concern.
What Are Push Back Racks Used For
Push back racks use a different mechanism: nested carts within each lane sit on slightly inclined rails. When a pallet is loaded at the front, it sits on the first cart. Loading another pallet pushes the previous pallet back onto the next cart, and so on.
When a pallet is retrieved from the front, the remaining pallets roll forward automatically — so loading and unloading happen from the same aisle. The system works under a Last-In, First-Out (LIFO) logic.
Push back racks are well suited for warehouses with limited floor space, multiple pallets per SKU, and inventories that do not require strict FIFO rotation.
Comparison: Pallet Flow Rack vs Push Back Rack
| Feature | Pallet Flow Rack | Push Back Rack |
|---|---|---|
| Inventory Flow Logic | FIFO (first-in, first-out) | LIFO (last-in, first-out) |
| Aisle Configuration | Requires two aisles: loading + picking | Single aisle: load and pick from same side |
| Storage Depth per Lane | Can be quite deep (many pallets per lane) | Typically 2–6 pallets deep per lane |
| Best For | High-turnover, perishable or date-sensitive items needing FIFO | High-density bulk storage, medium-turnover goods, uniform pallets |
| Forklift Traffic & Handling | Separation of load/unload reduces forklift interference | Load/unload in same aisle — less travel but careful pallet handling required |
| Flexibility for Multiple SKUs | Lower — each lane often dedicated to a single SKU | Higher — can store multiple SKUs across lanes and levels |
Evaluate product turnover and shelf life: For perishable goods or items requiring strict rotation, pallet flow (FIFO) is safer and more reliable.
Assess storage depth needs: If storing many pallets of the same SKU deep, pallet flow may offer better lane depth. For moderate depth, push back is flexible and efficient.
Consider aisle space and warehouse layout: If floor space is limited and minimizing aisles is critical, push back’s single-aisle setup saves space. If forklift traffic and separate load/unload operations are viable, pallet flow may improve throughput.
Pallet uniformity matters: Push back systems work best with uniform, consistent pallets. Pallet flow systems require good-quality pallets for smooth roller movement.
SKU variety and turnover mix: For warehouses with mixed SKUs — some fast-moving, some slow — a hybrid approach might work best: pallet flow for fast movers needing rotation; push back for bulk storage of slower or medium-turnover goods.
Plan for maintenance and operational complexity: Pallet flow includes rollers, braking systems, and two aisles. Push back has carts and rails but simplifies aisle design.
Improve Warehouse Storage Efficiency with Heda Shelves
With careful planning, warehouse owners can use racking solutions such as those offered by Heda Shelves to maximize storage density while preserving operational efficiency. By analyzing SKU turnover, inventory rotation needs, pallet quality, and floor layout, it becomes possible to design a custom racking system.
This system can combine pallet flow zones for perishable or FIFO-critical goods and push back zones for uniform bulk inventory — achieving a balance of density, speed, and flexibility. Such tailored designs reduce forklift travel, optimize space usage, and support safer, more organized warehouse flow.
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