High Density Pallet Rack Storage & Retrieval Systems

Store Pallets Up to 10 Deep - How It Works

The Short Answer: Chains on Rails

A Pallet Rests on the Maximum Density Flow Rails

Placing Pallets:

This Exglobe pallet storage system is built around its revolutionary flow rail design. The heart of the flow rail system is a unique patented chain that slides on top of an aluminum track. The chain features a specially punched pattern that securely grips the bottom of most pallets.

Weight of existing pallets is dispersed evenly across the system allowing the pallets to float atop the flow rail. The chain and rail system evenly disperses each pallet's load weight within the storage lane while the Exglobe patented track design drastically reduces the friction normally associated with pushing and/or pulling existing pallet loads atop the track.

By minimizing friction and evenly dispersing the overall weight of pallets within the system, the inertia required to move the track and the pallet within the lane is drastically reduced. This allows the force of a single pallet in contact with the rail chain to provide enough force to move all pallets in a lane up to 10 pallets deep. When the first pallet is placed on the rails, the pallet simply rests on the chain at the front of the rails. As each successive pallet is placed on the rails, it pushes the ones behind it which makes the chain slide backward along the rails.

Maximum Density Flow Rail Chain

Removing Pallets:

As pallets are removed from the system, the pallet to be removed is pulled out of the rack by a fork truck. The lift truck keeps the front of the pallet resting on the chain so that the chain (and all of the remaining pallets) slide forward along the aluminum rails. In this manner, the maximum density flow rail allows the operator to pick pallets from the aisle as one does with push back rack systems. This reduces damage and increases productivity eliminating the need to drive into storage lanes to retrieve pallets as typically associated with traditional drive-in rack or drive-thru racking systems.

Perhaps the best way to visualize the placement and removal of pallets in this flow rack system is to view a few short videos.

Loading and Unloading the Maximum Density Flow Rail System

Loading the maximum density flow rail system

Unloading the maximum density flow rail system

Comparisons to Other Rack Systems

Pushback Rack
Maximum Density Flow Rail   Pushback Rack Graphic   Pallet Flow Rack Graphic

Above: A comparison of a traditional pushback, or pallet flow rail system. Notice how much storage space is lost in the pushback system due to the incline needed for dynamic movement.

Comparison to Push Back Rack Systems

For starters, pushback rack is usually limited to a depth of 6 pallets. The maximum density flow rail system can hold pallets up to 10 positions deep! Another important difference between traditional dynamic rack systems and Max-density flow rail is that there is no need for an incline to move pallets forward with the flow rail system. Look closely at the two images above. In the traditional pushback system, nearly an entire level of pallet storage is lost due to the incline.

Removing the carts from the pushback system also cuts down overall weight. This can allow higher levels of storage with a max-density flow rail system. When pallets are loaded into a traditional pushback or pallet flow storage rack, the top products make contact with one another because of the angle needed for correct dynamic movement. In this situation, goods or packaging may be damaged. With the Max-density flow rail, the only contact between loads happens between pallets - if at all!

Pushback carts can be finicky, often jamming or derailing. This requires an employee to enter the rack structure to diagnose, and often unload a pallet which is unsafe at best. The Maximum Density Flow Rail cannot derail or produce blocks within the system.

Comparison to Pallet Flow Systems

Like push back rack, pallet flow can also be finicky when adjusting the inline brakes. The problem arises when a used adjusts the brake for a specific weighted pallet. Any other pallets placed in that lane must also weigh the same. If pallets are too light, they can get stuck on the brakes at the rear system causing an unsafe situation where a user must enter the rack to 'unstick' the pallet.

Likewise, with pallets that are too heavy, an unsafe condition is created where the pallet may rush down the track without sufficiently slowing. If the pallet has enough momentum by the time it reaches the bottom of the flow rails, it could potentially tip over onto a user who is at the front of the lane.

Maximum Density Flow Rail Configurations

Maximum Density Integration Into Traditional Rack Systems

As you can see , maximum density flow rails can be easily integrated into existing traditional rack systems. This product can turn regular static racking into a fully dynamic storage system while also making room for more product in the same amount of space.

Information for Forklift Operators

Fork Grips

Though not always necessary for proper stocking and picking operations, fork grips (pictured) are recommended. Our operators have found that after a short time, they no longer need the grips, but were glad to have them when they first started working with this system.

Procedure to Load Pallets

If the lane is empty, the pallet will be loaded just like in any selective rack system. The pallet (centered in position) will enter the rack 2-3 inches above the rails and be gently set down onto the tracks. It is important that the pallet DOES NOT touch the tracks while you are loading it. Also note - you should NOT side-shift the pallet while it rests on the tracks. The pallets must be centered on the rails before setting them down.

If pallets are already in the lane, you can use the front of the first pallet as a placement guide. Enter the pallet all the way in and then pull it back approximately 2". Make sure the pallet is centered and then lower it onto the tracks. The 2" back-up is recommended to avoid contact between the goods on the pallets.

Tilting a pallet to remove it from the system

Procedure to Unload Pallets

To unload a pallet, simply enter the pallet with the forks, tilt forward, and back-up. The front of the pallet should not be tilted more than 1" off the rails. If the pallet is tilted too much, not enough wood will remain on the chains to grip and properly move the track. Conversely, if the forks are not tilted enough, there will be too much wood on the chains and the pallet could slide off of the forks (this is prevented by the fork grips). As soon as the pallet is out of the system, make a full stop and then continue to back-up. This small stop will prevent the next pallet in the lane from accidentally rolling out of the system.

If you're interested in learning more about this unique new product and how you can immediately integrate it into your facility, please call (320) 485-4974 (direct sales line), (800) 598-5532 or Email Us.

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Pallet Racking Systems Shipping Locations - We Ship NATIONWIDE

Pallet Racks Stocking Locations

SJF Material Handling Inc. ships warehouse racking systems from multiple locations:

  • California
  • Georgia
  • Illinois
  • Massachusetts
  • Michigan
  • Minnesota
  • North Carolina
  • Pennsylvania
  • South Carolina
  • Texas
  • Utah
  • West Virginia
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