Boost Warehouse Efficiency with Carton Flow Racking: What You Need to Know
In today’s fast-paced warehouse environments, maximizing efficiency while minimizing space and labor costs is the name of the game. One solution that continues to prove itself across industries is carton flow racking. But what exactly is it, and why should you consider implementing it in your facility?
Let’s break it down.
What Is Carton Flow Racking?
Carton flow racking also known as gravity flow racking , is a type of dynamic storage system designed for high-volume, low-SKU order picking. Unlike static shelving, carton flow uses sloped roller tracks or wheels that allow cartons or totes to move forward via gravity as items are picked.
It’s commonly used in distribution centers, food and beverage facilities, and retail warehouses—especially in first-in, first-out (FIFO) inventory systems.
“Carton flow systems can reduce labor costs by up to 75% compared to static shelving by reducing walking and improving pick efficiency.”
— MHIA (Material Handling Industry of America)
Key Benefits of Carton Flow Racking
✅ Improved Picking Efficiency
Pickers spend less time walking or searching for inventory. Items are automatically presented at the front of the rack, meaning faster order fulfillment and fewer errors.
✅ FIFO Inventory Rotation
Because cartons are loaded at the back and picked from the front, inventory automatically rotates, helping reduce spoilage for perishable or time-sensitive products.
✅ Space Optimization
Carton flow racking allows for high-density storage with better cubic utilization compared to standard shelving. It also integrates well beneath pallet racks, creating a multi-level picking system.
✅ Reduced Labor Costs
Less walking and searching = fewer pickers needed to handle the same volume. Plus, ergonomics improve, reducing injury risk.
“Switching to carton flow racking can cut travel time during picking by as much as 80%.”
— Warehouse & Logistics News
Is Carton Flow Right for Your Operation?
While carton flow racking offers many advantages, it’s not a one-size-fits-all solution. Here are a few things to consider:
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SKU Velocity: Ideal for fast-moving items with consistent carton sizes.
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Order Profiles: Best suited for high-volume, piece or case picking operations.
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Upfront Costs: Carton flow can be more expensive initially than static shelving, but the ROI often comes quickly through labor savings and efficiency gains.
Common Applications
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E-commerce fulfillment centers
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Automotive parts distribution
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Grocery and cold storage facilities
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Manufacturing kitting lines
“Facilities that have implemented carton flow systems report significant gains in throughput and accuracy—critical in today’s same-day delivery world.”
— Modern Materials Handling Magazine
Integrating Carton Flow with Other Systems
Carton flow racking plays nicely with other systems. Many warehouses pair it with:
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Pallet racking: Carton flow underneath, reserve stock above.
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Pick-to-light systems: To increase speed and reduce errors.
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Conveyor systems: To create continuous picking lines.
This modularity allows businesses to scale their operations as needed without major overhauls.
Final Thoughts: The ROI of Efficiency
If your warehouse is plagued by picking bottlenecks, poor SKU rotation, or wasted space, carton flow racking might be the strategic upgrade you need. Its ability to streamline operations, increase throughput, and improve worker safety makes it a proven asset in any lean warehouse strategy.
And while the upfront investment may seem higher than static shelving, the long-term gains in labor savings, order speed, and inventory control can easily justify the cost.
Interested in upgrading your warehouse?
Contact us today to get a free quote and layout consultation.
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