Carton Flow Racking Systems Utah

Name: Carton Flow Racking
Brand: Rocky Mountain Warehouse Solutions
Availability: InStock

Carton flow racking integrated with conveyor system

Why Choose Carton Flow Racking?

Carton flow racking, also called case flow racking, uses inclined roller or wheel tracks to gravity-feed cartons from the replenishment aisle to the pick face, creating a continuously replenished, first-in, first-out pick front. As a picker removes a carton from the pick face, the next carton in the lane slides forward automatically, eliminating the need for pickers to reach into the shelf or reposition product. Carton flow is a core component of modern pick module design and one of the most effective ergonomic improvements a distribution center can implement, reducing picker travel time by up to 50% compared to static shelving. The productivity case for carton flow is well-established. In a traditional static shelving pick environment, pickers travel the full length of the pick aisle and reach into shelves at varying depths to retrieve each item. In a carton flow environment, the pick face is always full, product is always at the front of the lane, and the ergonomic pick position is consistent, reducing both travel time and the physical strain of deep-reaching into shelves. For high-velocity SKUs in particular, the constant forward presentation of fresh inventory enables a picking rhythm that static storage cannot match. Rocky Mountain Warehouse Solutions designs and installs carton flow systems as standalone pick bays or as part of complete multi-level pick modules with conveyor integration. We specify wheel track spacings and lane widths based on your carton size profile, configure lane depth based on replenishment frequency, and integrate the system with your WMS pick locations. Systems are installed on standard teardrop pallet rack frames in most cases, making carton flow a cost-effective upgrade to an existing racking investment.

Reduces picker travel time by 40–60%
Continuous FIFO replenishment from the rear
Ideal for high-velocity pick operations
Integrates with pick module and conveyor systems
Multiple wheel track spacings for carton size variety
Gravity-powered: no electricity required
Compatible with WMS pick systems

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Technical Details & Buying Guide

Carton flow systems use either wheel tracks (rollers with individual plastic wheels on a steel axle) or skatewheel tracks (continuous rows of small plastic wheels) to support and move cartons down the inclined lane. Wheel track spacing (the distance between parallel tracks) is selected based on the minimum carton width in the system. For a mix of carton sizes, adjustable wheel track systems allow lane width to be changed without replacing components. Track inclination is typically 3/8 to 5/8 inch per foot, providing enough gravity to move cartons forward without excess speed at the pick face.

Lane depth in carton flow is determined by your replenishment cycle. If a replenishment operator restocks lanes once per shift, lanes should be deep enough to hold a full shift's worth of picks for each SKU without running empty. For high-velocity SKUs, this may mean 8–12 carton deep lanes; for slower-moving SKUs, 3–5 carton depth is typically sufficient. Lane dividers allow a single shelf level to accommodate multiple lane widths, maximizing the number of pick faces per vertical foot of racking height. Ergonomic pick heights, typically 28 to 52 inches above the floor, are the most productive and should be assigned to the highest-velocity SKUs.

Carton flow integrates naturally with pick-to-belt and pick-to-conveyor systems. In a pick module, the carton flow pick face is positioned directly above or adjacent to the take-away conveyor, allowing pickers to immediately deposit picked items onto the belt without carrying them. The separation of replenishment (from the back aisle) and picking (from the front aisle) allows replenishment and picking to occur simultaneously without congestion, further improving throughput. Lane position indicators, put-to-light systems, and pick-to-light systems are commonly integrated with carton flow to guide pickers and reduce errors in high-SKU-count environments.

Industries We Serve

E-commerce fulfillmentDistribution and logisticsFood and beveragePharmaceuticalThird-party logisticsRetail replenishment

Common Use Cases

Piece-pick order fulfillment

Case-pick distribution

Pick module design

High-velocity SKU storage

Ergonomic picking at proper height

FIFO product rotation

Frequently Asked Questions

What is the difference between carton flow and pallet flow?

Carton flow handles individual cartons and cases using wheel or roller tracks sized for case dimensions (typically 4–24 inches wide). Pallet flow handles full pallets on heavy-duty roller lanes. Carton flow is used in piece-pick and case-pick operations; pallet flow is used for bulk pallet storage and replenishment.

Can carton flow be added to existing pallet racking?

Yes. Carton flow tracks can be retrofitted into existing teardrop pallet racking using universal rail kits that clamp onto standard beam steps. This is a cost-effective way to convert static shelving bays to high-productivity pick faces without replacing the structural racking frame.

What carton sizes can carton flow handle?

Standard carton flow systems handle cartons from approximately 4 inches to 24 inches wide and from 3 inches to 12 inches tall. For smaller items, dividers can be added to create narrower lanes. For very heavy or oversized cartons, heavy-duty wheel tracks with closer spacing and steeper inclination maintain reliable gravity flow.

How do I determine the right lane depth for carton flow?

Lane depth is driven by replenishment frequency and SKU velocity. For high-velocity SKUs picked hundreds of times per day, deep lanes (8–12 cartons) reduce replenishment frequency. For slower SKUs, 3–5 cartons deep is usually adequate. We size lanes based on your SKU velocity data to minimize replenishment labor while keeping pick faces stocked.

What is a pick module?

A pick module is a multi-level storage and picking structure that combines mezzanine levels, carton flow racking, pallet flow racking, and conveyor systems into an integrated order fulfillment operation. Multiple pick levels are connected by a take-away conveyor that collects picked items from each level and routes them to packing and shipping. Pick modules can dramatically increase pick productivity in high-SKU, high-volume operations.

Is Carton Flow Racking Right for Your Facility?

Available options: New, certified used, and custom-configured systems
Installation: Professional installation and teardown by our trained crews
Layout support: CAD-based warehouse layout assistance included
Service area: Utah, Nevada, Idaho, Colorado, Arizona, Wyoming, and Montana
Response time: Quote within 1 business day. Site visits available.

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Available in major service areas

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Carton Flow Rack for Order Picking & Fulfillment