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dynamic gravity flow

Accelerate Fulfillment With
Carton Flow Racking Systems

Transform high-touch order fulfillment with dedicated gravity-fed pick lanes. By separating rear inventory stocking from front pick faces, carton flow systems eliminate aisle congestion, enforce strict FIFO rotation, and slash order-picker travel distances by up to 75%.
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gravity-fed efficiency

Condense Pick Faces &
Supercharge Picking Velocity

Carton flow racking channels inventory down inclined roller tracks or skatewheel beds, automatically feeding cartons forward to the pick face as front items are retrieved. By consolidating hundreds of SKUs into compact, multi-tier pick modules, pickers spend less time walking and more time fulfilling orders. Rear loading lanes allow stockers to replenish inventory continuously without interrupting active order selectors, eliminating bottleneck delays in fast-moving fulfillment centers.
Design
carton-flow pallet racking organized against a warehouse wall.

productivity advantages

Why Choose Carton Flow Racking

Cut labor expenses and accelerate high-volume piece and case picking with gravity-powered lane architecture.

75% Travel Time Reduction

Condenses pick faces so warehouse selectors fulfill more orders per hour without walking endless static aisles.

Automatic FIFO Stock Rotation

Gravity feeds cases forward so older inventory is selected first, preventing date code expiration and obsolescence.

Segregated Stocking & Picking

Restock from rear aisles while pickers operate uninterrupted at the front face, eliminating aisle traffic jams.

Universal Case & Tote Fit

Handles corrugated cartons, plastic split-case totes, and irregular boxes with adjustable full-width rollers or wheel beds.

Drop-In Rack Integration

Retrofit existing teardrop or structural pallet rack bays into high-velocity pick modules using drop-in shelf tracks.

Pick-to-Light & Conveyor Ready

Integrates smoothly with digital pick-to-light displays, barcode scanners, and take-away roller conveyor lines.

High SKU Pick-Face Density

Packs up to 40 distinct SKU pick lanes per standard rack bay, multiplying storage capacity over static shelving.

Maintenance-Free Gravity Operation

Operates purely on gravity with zero motors, electrical power draw, or complex drive components.

DYNAMIC GRAVITY FLOW

High-Velocity Case Picking
With Carton Flow

Consolidate Pick Faces & Slash Travel Time

Replace static shelving with gravity-fed carton flow tracks. Enforce strict FIFO rotation, eliminate congestion with separate stocking aisles, and boost pick rates up to 75%.

Custom Lane Engineering

Optimal pitch, roller width, and lane dividers tailored precisely to your carton profiles.

Fast Retrofit or New Modules

Mount directly into existing pallet rack bays or deploy standalone multi-tier pick modules.

Turnkey Fulfillment Design

Seamless integration with pick-to-light, RF scanning, and takeaway powered conveyors.

SUPERCHARGE PICKING VELOCITY

Get a Carton Flow Quote

Provide your carton dimensions, weights, and SKU counts to receive a custom track configuration.

Provide phone, email, or both — at least one is required.
No obligation. We never sell or share your contact information.

faqs

Frequently Asked Questions

Straight answers to common questions about carton flow track types, weight limits, and retrofit options.

How does a gravity carton flow rack system work?

Carton flow racks use gently sloped shelf beds equipped with durable polycarbonate or aluminum roller tracks or skatewheels. Cartons and totes are loaded from the rear (charge end) and roll forward by gravity toward the front (discharge/picking end). When an operator picks the front carton, the next box in line automatically glides forward to take its place at the pick face.

How does carton flow improve warehouse picking productivity?

In traditional static shelving, up to 70% of a picker's shift is spent walking aisles searching for SKUs. Carton flow condenses dozens of pick faces into a single bay and keeps items flush at the front edge. With separate replenishment aisles at the rear, pickers work without interruption, typically boosting picking rates by 50% to 75% while cutting order cycle times.

Can carton flow tracks be retrofitted into existing pallet racking?

Absolutely. Most carton flow tracks, such as span-track or dedicated shelf-drop tracks, are designed to mount directly onto existing pallet rack step beams with universal hanger brackets. You can convert the lower levels of your current teardrop or selective racking into carton flow picking bays while keeping pallet storage overhead.

What types of cartons, boxes, and containers run smoothly on carton flow?

Carton flow accommodates corrugated cardboard cartons, molded plastic totes, returnable distribution containers, and split-case trays. Systems with full-width steel or polypropylene rollers provide maximum surface contact for soft or creased cardboard bottoms, while skatewheel track beds offer flexible multi-lane lane dividers for varying carton widths.

How do you adjust the slope and lane dividers for different product weights?

Shelf pitch is easily adjusted—typically between 3/8-inch to 1/2-inch of fall per foot—to ensure steady flow without excessive speed. Heavy cases use impact-dampening entry plates and optional speed controllers, while snap-in lane dividers keep product lanes organized and prevent cross-lane jamming.

What is the typical ROI period for a carton flow installation?

Most distribution centers and fulfillment operations recoup their investment in carton flow racking within 6 to 12 months. Savings stem directly from reduced picker travel labor, lower mispick rates, eliminated product obsolescence via strict FIFO, and reduced floor footprint requirements.

Do you offer installation and engineering services for carton flow racking?

Yes. We provide complete turnkey services including warehouse layout CAD design, stamped engineering calculations, local high-pile permit coordination, and certified nationwide professional installation.

Contact our engineering team today at sales@wdracks.com or call us at 1-877-969-3334 to get started.