Carton Flow Racks
Carton Flow Rack Systems
Faster picks at the carton level. Gravity-fed lanes keep product at the pick face, reducing walk time and improving ergonomics.
100% FIFO
Gravity-fed at every pick position
50%+ Faster
Picks vs. flat shelving
24"–72" Pick Zone
Positioned for your team
Carton flow racking is a gravity-fed, first-in, first-out (FIFO) order picking system designed for case-level and carton-level fulfillment. Tilted roller or wheel lanes present products at ergonomic pick heights, reducing travel time and improving pick rates in high-volume operations.
The Right Application
When Pick Speed and Rotation Discipline Both Matter
High-Velocity Pick Faces
In operations where pickers are hitting the same positions dozens of times a day, position accessibility and ergonomics directly affect throughput. Carton flow keeps product at the face without the picker reaching into empty space or waiting for replenishment.
Lot-Controlled Case Picking
For pharmaceutical, food, and beverage operations that track lot numbers at the case level, gravity-flow FIFO enforces rotation without relying on picker discipline or WMS enforcement at every position.
Replenishment-Heavy Operations
When replenishment runs interrupt pick operations, throughput suffers. Carton flow separates those two activities: replenishment happens from the back aisle while picking continues uninterrupted from the front face.
Technical Specifications
Key Specs & Configuration
| Lane Width | Configured to carton/case dimensions, custom per SKU or product family |
| Flow Type | Wheel beds, roller tracks, or full-width rollers, selected by case weight and dimensions |
| Inventory Method | FIFO: load from rear aisle, pick from front face |
| Integration | Installs on selective racking or standalone; integrates into pick module designs |
| Best For | Order fulfillment, e-commerce, case picking, pharmaceutical distribution |
| Ergonomics | Pick face tilted toward operator, reduces reach distance and picker fatigue |
| Code Notes | Standard racking permits; additional engineering required if integrated into pick modules |
Brands We Carry
Built With Industry-Leading Components
How It Works
Designed Around Your Pick Face
Carton flow rack uses inclined roller or skatewheel lanes, typically in a selective rack frame, sized for your case dimensions. Cases load from the rear and flow forward under gravity to the pick face. Speed controllers prevent cases from arriving too fast or building pressure at the face.
Lane width and roller spacing are configured for your case dimensions, and we design pick face ergonomics around your picker's reach range, typically waist-to-shoulder for high-velocity picks. Systems can be single-deep (one case flows at a time) or multi-deep (several cases queue behind the front position) depending on your replenishment frequency needs.
Carton flow effectiveness depends entirely on lane configuration matching your actual carton sizes and weights. We measure product dimensions, test flow angles, and design lane widths that prevent jamming. We also integrate carton flow into larger pick module designs when your operation requires a multi-level solution.
What You Get
Built In, Not Bolted On
Roller or Skatewheel Lanes
Lane type selected for your case weight and dimensions: roller for heavier cases, skatewheel for lighter cartons. Both deliver consistent gravity flow to the pick face.
Separated Replenishment
Replenishment from the rear aisle while picking continues from the front, no picker interruptions and no traffic conflict.
Engineered and Permitted
Full structural engineering, stamped drawings, and permit records. Flow lane specifications documented for future reconfiguration.
Best Suited For
Common Applications and Industries
Retail Distribution
Fast-moving pick faces for store replenishment operations with high daily pick counts.
Medical & Pharma
FIFO case rotation for lot-controlled inventory without manual discipline requirements.
Food & Beverage
Date-sensitive case picking with automatic rotation and clean pick faces.
Third-Party Logistics
Pick-face efficiency for high-volume clients with repeatable daily order profiles.
Related Services
We Handle Design, Installation & Permitting
I have been working with Hammerhead for a few months now and can say with absolute certainty that this is a great team to work with on your warehousing needs! They are very responsive on all matters and work in great timeframe to make everything as seamless as possible for everyone.
Jared Kern
Google Review
Other Systems to Consider
Related Storage Systems
Pallet Flow Racks
FIFO gravity flow at the pallet level. Pairs with carton flow for reserve-to-pick systems.
Learn More →
Selective Pallet Racks
Reserve pallet storage that feeds carton flow pick faces.
Learn More →
Pick Modules
Multi-level integrated systems combining carton flow, selective reserve, and conveyor components.
Learn More →FAQ
Common Questions
Can carton flow handle multiple carton sizes in the same system?
Yes, each lane is configured independently. A single carton flow system can have lanes sized for different carton dimensions side by side. We design lane widths based on your actual SKU profiles, grouping similar sizes where possible for simpler replenishment.
How much can carton flow reduce labor costs?
Labor savings come from two sources: faster pick cycles because product is always at the face, and eliminated wasted time from replenishment interruptions during active picking. The actual reduction depends on your current pick rates, SKU count, and replenishment frequency. We can model the impact based on your operation before you commit.
Can carton flow be retrofitted to existing selective racking?
Yes, carton flow lane inserts can be installed into most existing selective rack bays without replacing the uprights or beams. The retrofit approach is common for operations that want to convert a portion of their selective rack to flow positions without a full system replacement.
Optimizing Your Pick Operations?
We'll evaluate your SKU profiles and design carton flow lanes that match your actual product dimensions. Free consultation, no obligation.
Schedule a Site Visit