Carton Flow Rack Systems
Gravity-fed roller or wheel lanes built into pallet rack bays for organized, FIFO case and carton picking. Load from the back, pick from the front — every SKU always in the same place.
Talk with a pallet rack specialist. Call (800) 326-4403 or Email Sales@MH-USA.com
What Is Carton Flow Rack?
Tilted roller or wheel-bed lanes installed inside pallet rack bays that use gravity to move cartons, cases, and totes from the loading side to the picking face — automatically.
Carton flow rack (also called case flow, gravity flow, or pick rack) converts standard pallet rack bays into organized, high-density carton picking stations. Inclined lane sections with rollers or wheel beds are placed on pallet rack beams. When a carton is loaded at the back, gravity slides it forward to the pick face at the front. When the front carton is picked, the next one rolls into position.
The result: every SKU always has a carton at the pick face. No reaching, no searching, no wasted steps. Order pickers work a single aisle face and pull exactly what they need in sequence. Pick rates increase 2–3× compared to static shelving, and FIFO rotation is automatic — critical for food, beverage, pharmaceutical, and any operation with lot-tracked or expiration-dated inventory.
Material Handling USA designs, supplies, and installs carton flow rack systems for distribution centers, e-commerce fulfillment, manufacturing kitting lines, and cold storage operations nationwide.
Carton Flow Track Types
Wheel Bed (Skatewheel)
Multiple small skate wheels mounted on axles in a formed steel channel. The most common and cost-effective type. Handles light to medium cartons (5–50 lbs). Wheels adjust to different carton widths and bottom surfaces. Easy to install and replace.
Best for: E-commerce, retail distribution, general case picking
Full-Width Roller
Steel or plastic rollers spanning the entire lane width. Handles heavier loads (up to 75+ lbs per carton) and wider products. More robust than wheel beds but higher cost per lane. Consistent flow for uniform-sized cartons.
Best for: Beverage, heavy consumer goods, uniform case sizes
Knuckled Track / Tilt Tray
Hinged or tilting lane sections that can be adjusted for different product depths and weights. Some systems use spring-loaded speed controllers or brakes to regulate carton flow speed and prevent pile-ups.
Best for: Multi-SKU operations with varied carton sizes and weights
How Carton Flow Rack Works
Load from Rear
Replenishment crew loads full cases from the back (stock) aisle. Separate aisle from pickers eliminates congestion.
Gravity Flow
Tilted lanes use gravity to slide cartons forward on rollers or wheels. No power, no motors — 100% passive.
Pick from Front
Order pickers work the front (pick) aisle. Every SKU has a carton at the face. Pull what’s needed — next carton rolls into place.
Auto FIFO
First carton loaded is always the first picked. Automatic rotation — no manual date-checking or stock shifting.
Technical Specifications
| Parameter | Carton Flow Rack | Notes |
|---|---|---|
| Track Types | Wheel bed, full-width roller, knuckled | Choose by carton weight and bottom surface |
| Lane Width | 6″ to 36″+ per lane | Adjustable dividers available |
| Lane Depth | 4 to 8+ cartons per lane typical | Standard pallet rack bay depth |
| Carton Weight | 5 to 75+ lbs per carton | Roller tracks for heavier loads |
| Incline | 3° to 5° typical | Adjustable for product characteristics |
| Flow Direction | FIFO — load rear, pick front | Automatic first-in, first-out rotation |
| Frame | Standard pallet rack beams & uprights | Drop into existing selective rack bays |
| Levels | 2 to 6+ flow levels per bay | Ergonomic pick heights available |
| Power | None — 100% gravity powered | No electricity, no maintenance |
| Speed Control | Available — brakes, speed controllers | Prevents carton damage at pick face |
Applications & Industries
📦 E-Commerce Fulfillment
High-volume each-pick and case-pick operations. Carton flow organizes hundreds of SKUs at ergonomic pick heights, dramatically reducing walk time and increasing units picked per hour.
🍔 Food & Beverage Distribution
Automatic FIFO for expiration-dated products. Separate load and pick aisles keep production moving. Cold storage rated options available for cooler and freezer environments.
💊 Pharmaceutical & Medical
Lot-tracked inventory requires strict FIFO. Carton flow provides automatic rotation, clear SKU labeling positions, and audit-ready organization for regulated facilities.
🏭 Manufacturing Kitting
Line-side carton flow delivers components to assembly stations in order. Pickers pull kits from organized, replenished lanes — reducing production line stoppages.
🛒 Retail Distribution
Store replenishment picking from carton flow racks. Each store’s order is picked from a single aisle face with every SKU visible and accessible. Case-level picking at maximum speed.
🔧 Auto Parts & Hardware
Hundreds of small-to-medium SKUs organized in divided flow lanes. Wheel bed tracks handle varied box sizes. Easy to reconfigure when product mix changes.
Carton Flow vs. Other Picking Systems
| System | Pick Speed | FIFO | SKU Density | Cost | Best For |
|---|---|---|---|---|---|
| Carton Flow Rack | ★★★★★ | Automatic | High | $$ | Case/carton picking, FIFO required |
| Static Shelving | ★★ | Manual | Low | $ | Low-volume, few SKUs |
| Standard Selective Rack | ★★★ | Manual | Medium | $ | Pallet-level picks |
| Pallet Flow Rack | ★★★★ | Automatic | High | $$$ | Full-pallet FIFO |
| Automated Pick Systems | ★★★★★ | System-controlled | Very High | $$$$ | Extremely high volume |
Choose carton flow if: You pick at the case or carton level, need FIFO, have a moderate-to-high number of SKUs, and want to dramatically increase pick rates without automation investment.
Frequently Asked Questions
Yes — carton flow tracks are designed to drop into standard pallet rack bays. If you have existing selective rack, you can convert specific bays to carton flow without replacing the rack structure.
Typically 4 to 8 cartons deep per lane, depending on bay depth and carton size. Standard 48″ deep pallet rack bays accommodate 4–6 cartons; deeper bays can hold 8+.
No. Carton flow is 100% gravity powered — the lanes are tilted slightly so cartons roll forward on wheels or rollers. No electricity, no motors, no maintenance on drive systems.
Adjustable lane dividers let you configure different lane widths within the same bay. Wheel bed tracks handle varied bottom surfaces better than rollers. Many operations dedicate different bays or levels to different carton sizes.
Most operations see 2–3× improvement in picks per hour compared to static shelving. The gains come from reduced walk time, instant SKU visibility, and eliminated search time.
Same concept, different scale. Pallet flow rack moves full pallets on heavy-duty rollers. Carton flow moves individual cartons and cases on lighter wheel beds or rollers within a pallet rack bay.
Explore More Pallet Rack Solutions
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Material Handling USA designs and installs carton flow rack systems for distribution centers, e-commerce fulfillment, and manufacturing operations nationwide. Free design consultation and layout.