Pallet Flow Racks
Pallet Flow Rack Systems
Automatic FIFO rotation for high-throughput operations. Load from the back, pick from the front. Gravity does the rest.
100% FIFO
First in, first out every time
Up to 20 Deep
Lanes sized to your throughput
Full Brake System
Speed governors on every lane
Pallet flow racking is a gravity-fed, first-in, first-out (FIFO) warehouse storage system where pallets are loaded at the back and roll forward on inclined roller lanes to the pick face. It is used in facilities with date-sensitive inventory such as food, beverage, and pharmaceutical products.
The Right Application
When Rotation Discipline Is Not Optional
Expiration and Lot Control Requirements
Food, beverage, pharmaceutical, and chemical products have hard expiration dates. When manual FIFO discipline fails (and in high-volume operations, it will), product expires before pick and inventory records become unreliable. Pallet flow enforces rotation mechanically.
Replenishment-Intensive Pick Operations
Separating the replenishment aisle (rear) from the pick aisle (front) allows replenishment to happen without interrupting active picking. In high-throughput DCs, that separation meaningfully improves both replenishment speed and pick efficiency.
High-Volume Same-SKU Storage
Pallet flow lanes hold multiple pallets of the same SKU in a dense, gravity-fed queue. For operations with high volumes of a manageable number of SKUs, flow rack delivers density and FIFO in the same lane.
Technical Specifications
Key Specs & Configuration
| Storage Depth | 3–20+ pallets per lane depending on lane design |
| Load Capacity | 1,500–4,000 lbs per pallet position |
| Slope | Engineered pitch with speed controllers and/or pallet brakes |
| Inventory Method | FIFO: load from rear aisle, pick from front face |
| Best For | Perishable goods, date-sensitive inventory, high-volume distribution |
| Structural Notes | Requires speed controllers and/or pallet separators, lane-specific engineering |
| Lane Configuration | Roller type, spacing, and incline calibrated to your pallet weight and dimensions |
| Code Notes | High storage density triggers fire code review; in-rack sprinklers may be required |
How It Works
The Most Engineered Racking Type: Done Right
Pallet flow rack uses inclined roller lanes set inside a selective rack frame. Pallets load from the rear and travel down the incline to the pick face under gravity, controlled by speed reducers that prevent pallets from arriving too fast. When the front pallet is removed, the next one rolls forward automatically.
Pallet flow systems are the most engineered racking type. Roller specs, slope calculations, brake mechanisms, and speed controllers all need to match your exact pallet weights and product characteristics. Get it wrong and you get runaway pallets, damaged product, and stuck lanes. We size lanes for your specific pallet profile, set the incline and reducer spacing during commissioning, and document everything.
The system requires no motors or controls. Maintenance is periodic inspection of rollers and speed reducers. We design the system around your replenishment access from the rear aisle, separating replenishment traffic from pick traffic for maximum throughput.
What You Get
Built In, Not Bolted On
Gravity Roller Lanes
Steel rollers on inclined rails with speed reducers calibrated for your pallet weight. Pallets flow consistently without manual intervention.
Separated Load / Pick Faces
Replenishment happens from the rear aisle; picking happens from the front face. No traffic conflict between receiving and pick operations.
Engineered and Permitted
Full structural engineering, stamped drawings, and permit coordination. Roller lane specifications documented for maintenance reference.
Best Suited For
Common Applications and Industries
Food & Beverage
Expiration-critical inventory that requires mechanical FIFO enforcement.
Medical & Pharma
Lot-controlled pallets with strict FEFO requirements and regulatory traceability.
Third-Party Logistics
High-volume client SKUs that require rotation discipline without manual management.
Cold Storage
FIFO rotation in conditioned environments. Roller lanes perform in freezer temperatures.
Related Services
We Handle Design, Installation & Permitting
When it came to racking our distribution facility, they made the process easy. We purchased our racking from them and they installed it.
Chet Bloody
Google Review
Other Systems to Consider
Related Storage Systems
Carton Flow Racks
FIFO gravity flow for cases and cartons at the pick face level.
Learn More →
Selective Pallet Racks
Pairs with pallet flow for reserve storage where direct access is needed.
Learn More →
Push Back Racking
LIFO density alternative when strict FIFO rotation is not required.
Learn More →FAQ
Common Questions
What products are best suited for pallet flow racking?
Pallet flow works best for products that require FIFO rotation: food and beverage with expiration dates, pharmaceutical products with lot control requirements, and any high-volume SKU where date discipline matters. It also works well for any high-throughput DC with consistent pallet weights and enough volume per SKU to fill multiple lane positions.
What is the maximum lane depth?
Most installations run 5–12 pallets deep. Lanes can go to 20+ pallets with the right engineering, but very long lanes require more precise slope calibration and brake placement. The practical limit is usually your ceiling height and the depth available in your building before the lane becomes operationally impractical to manage.
How does pallet flow cost compare to selective or push back?
Pallet flow costs more per pallet position than selective or push back because of the roller lane components, speed controllers, and precision installation required. The ROI case is built on labor savings from eliminated manual FIFO discipline, reduced product loss from expiration errors, and improved throughput from separated pick and replenishment aisles. We can help you model the tradeoff for your specific operation.
Need FIFO Rotation for Perishable or Date-Sensitive Inventory?
Let us design a pallet flow system sized for your pallet profile: lane depth, roller spacing, and speed reducers all specified. Free site visit, no obligation.
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