What is Case & Carton Flow Rack?
If you are in any business where you do a lot of picking from inventory, Case & Carton Flow Rack is a product you should be aware of. With carton flow, you stock from the back and pick from the front. Pickers and stockers are kept out of each others way. If you are using regular static shelving, you know what a great benefit this alone will be.
A carton flow rack has several shelves, each shelf generally has 4 or 6 lanes. Specific products are assigned to each lane. As items are picked, the next item slides down to take its place at the face of the racking. Everything works using rollers and gravity (nothing motorized here). With a carton flow system, costs are kept low and efficiency is high.
Static Rack vs. Dynamic Rack
In a traditional static racking system such as pallet rack or bulk shelving (shown at left), the stocking and picking operations are often performed at the same time. This often causes interference as well as a lot of time wasted in travel.
With a dynamic system such as gravity flow, carton flow or spantrack (shown at right), the stocking and picking operations are kept separate to keep interference to a minimum.
A carton flow rack system can also help keep inventory better organized and can help with inventory concerns as all products and quantities are immediately visible. This allows inventory control specialists to keep track of product counts, shortages and other inventory concerns.
Choosing Carton Flow
Do you need a starter unit, an add-on unit or individual components?
- A carton flow starter unit includes two uprights, four, five or six shelves, roller guides, roller tracks and sway braces. Shelf clips are also included.
- A carton flow add-on unit includes one upright instead of two. The add-on unit can be used with the starter unit or your existing flow rack.
- Separate carton flow components may be purchased to replace or add to the system you have.
Flow Racks in Pallet Rack
Flow rack can be used in conjunction with pallet rack to maximize your storage space. The pallet rack can create storage above the flow rack system. To support the additional load 3”x3” posts replace the 1 ½” flow rack posts and heavy beams replace the sway braces. Using the Universal Hanger Clips in conjunction with carton flow shelves you can even turn your existing static pallet rack into a dynamic carton flow system.
Carton Flow Rack Components
Carton Flow Upright Frames
Frame sizes are 60", 66" or 96" wide and 60", 90" or 120" deep. All frames are 8' high (the 120" system is sold as a 2-piece unit). The frame is the basic supporting structure of the flow rack unit. Carton weight, size and throughput rates are variables to determine which model will deliver the desired results.
- 60" deep frames have a capacity of 6,000 lbs.
- 90" deep frames have a capacity of 8,000 lbs.
- 120" deep frames have a capacity of 12,000 lbs.
Frames have formed channels with a double row of slots to receive 3-prong clips for ½" vertical shelf adjust-ability. Columns are embossed with number scales for easy installation and adjust-ability.
Carton Flow Shelves
- The 60" deep unit requires a minimum of eight roller tracks and three guides per shelf. The capacity is 50 lbs. per lineal foot per lane with an evenly distributed load.*
- The 90" deep unit requires a minimum of ten roller tracks and four guides per shelf. The capacity is 50 lbs. per lineal foot per lane with an evenly distributed load.*
- The 120" deep unit requires a minimum of twelve roller tracks and five guides per shelf. The capacity is 50 lbs. per lineal foot per lane with an evenly distributed load.*
To determine the number of shelves required:
Number of Shelves = Available Height/Carton Height + 6.25"
(divide your available height by your carton height and add 6 ¼")
- Each lane in a shelf requires 2 roller tracks and 1 guide.
- Standard straight shelves have a 5 degree tilt. If you need knuckle or tilt tray shelves please call SJF at (800) 598-5532.
- The space between the top of a carton and the shelf above it should be large enough to allow each product to be removed freely.
- Shelf capacities are between 750-3,000 lbs.*
*Typical systems are designed for 25-30 lbs. per square foot, however these capacity ratings are ultimately dependent on the packages stored on the shelves. All packages must have evenly distributed weight so as not to create a point load situation on the roller tracks. If you have any questions about carton flow rack capacities, please call an SJF representative to discuss it.
The sway brace comes in two widths: 4" and 7". Sway braces are designed to make the frames stable. Four-inch sway braces are used on the top rear and bottom front of all units. Seven-inch sway braces are used on the top front of all units. All units are braced at the bottom rear and the 120" unit is braced at the top center.