Pallet Flow Rack

Pallet flow rack, also known as “gravity flow,” is a FIFO (first in, first out) dynamic storage system. With pallet flow, you can achieve high-density storage while maintaining a FIFO retrieval order. Pallet flow racking maximizes actual storage space by minimizing aisles. Pallet flow systems can be designed to hold up to 20 pallets deep in one lane and allow for quick and efficient inventory turnover.

Customization is the key to effective pallet flow racking systems and manufacturers offer different types of rollers designed to serve different applications. Some manufacturers can even customize their pallet flow racks with speed controller capacities that are uniquely designed for users’ product weight ranges.

We have decades of experience designing pallet flow systems. We’re here to help you create a system that exceeds your expectations and improves your storage efficiency. Ready to move forward with your pallet flow project? Get in touch today to learn more or get a quote.


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How Pallet Flow Rack Works

Pallet flow rack systems are generally first in, first out (FIFO). In a flow rack system, pallets are loaded into the storage lane from the loading aisle and fed by gravity towards the discharge aisle.

The pallets are first placed on the rollers that let them “flow” towards the front of the rack system. Once they’ve glided to the front of the system, the pallets rest on pallet stops until they’re unloaded from the pick face.

As pallets are removed or unloaded from the system, each of the pallets that were behind them rolls forward one position. This process can happen until the lane is empty or indefinitely if pallets are loaded into the system. Pallet speed is controlled by the type of rollers and brakes engineered into the system.

Types of Pallet Flow Rack Lanes:

Full-width rollers: Because of their width of support, these are ideal for applications with multiple pallet sizes for products. Full-width rollers are also the most flexible pallet flow roller option available on the market.

Magnum (Poly) Wheel Rollers: These are the most durable type of pallet flow roller available. Magnum wheel rollers are ideal for pallet loads reaching over 3,000 pounds and are perfect for freezer storage applications.

Skate Wheel Rollers: Skate wheel rollers are typically used with standard wood pallets in pallet flow systems that have short lanes. Skate wheel rollers are generally the most cost-effective pallet flow roller option.

Pallet Flow Rack Safety

    • Safe Loading 

In pallet flow rack systems, pallets are loaded onto one side of the system and move via roller track to the other end where they’re unloaded.  It’s important to properly place pallets on the loading end of the rack system, being careful not to collide with the racking.

If pallet flow is being used for a push-back application, operators should be use caution when pushing the pallets backward on the system.

    • Safe Unloading 

Once pallets have been carried via gravity to the unloading end of the rack system, they’ll sit there until unloaded.  The pallet being unloaded is the only barrier between the next pallet in line and the front of the system, so forklift operators should be unloaded slowly to encourage a smooth transition.

    • Maintenance 

Proper maintenance is the key to keeping your warehouse safe and preventing your pallet rack from losing its strength and stability.  Like other pallet rack systems, we advise performing routine safety checks on pallet flow systems in order to monitor the system’s structural integrity and verify the proper function of its parts.

Specifically, wheel beds or roller tracks should be thoroughly inspected to ensure pallets will properly flow and remain on the track when moving through the system.

Download the Pallet Flow Rack infographic


Advantages of Pallet Flow:

    • Space-saving, high density storage
    • Customized, tailor-made design and layout
    • Dynamic “flowing” warehousing
    • Fast — Immediate access to every product
    • Versatile — Well-suited to refrigerator or freezer storage applications
    • Practical and efficient
    • Operator friendly
    • Tested for your unique application
    • Time-saving — only one input and one output aisle
    • Minimal maintenance and reliable
    • References from all types of industries


Pallet Flow Pallet Rack Components

Gravity flow rack systems are made up of two main parts:

The rack structure: depending on your application environment, pallet flow racking can be engineered with either structural or roll formed pallet rack, offering you the best solution for your operations.

Pallet flow wheels, rails and brakes: These components are all selected based on the individual application.


Magnum (poly) wheel rollers can support loads in excess of 3,000 pounds


Pallet Flow Frequently Asked Questions:


    • How many pallets deep can pallet gravity flow hold?

Most pallet flow rack systems can hold anywhere from 2 to 25 pallets per lane.  However, custom-engineered pallet flow systems can be designed to store an even greater number of pallets per lane if necessary.

    • What is the estimated lead time for a pallet flow project?

Lead times for pallet flow projects are similar to other engineered rack systems, which generally hover in the 8 to 12-week range.  Lead times can be influenced by the approval process, but otherwise remain fairly static.

    • What is the typical pitch of a Pallet Flow Lane?

The pitch of a pallet flow lane can vary from system to system.  That being said, the most common pitch given to pallet flow lanes is 1/2” per linear foot.  To illustrate this, imagine a pallet flow lane that is 20’ long.  If the pitch is 1/2” per linear foot, the loading end of the lane will be 10” taller than picking end.  This slant allows the pallet to “flow” effortlessly from one end of the system to the other.

Have more questions that we haven’t answered here? Reach out to us and we’ll be happy to answer any questions you have about pallet flow racking!


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