Similar to Pallet Flow, Carton Flow is a gravity based system, but for smaller loads commonly placed in boxes. This warehouse system is FIFO (first in first out), with products automatically rotated due to the nature of the picking. Carton Flow always keeps the merchandise within reach and it is easy to monitor since everything is always visible.
General Characteristics
The Carton Flow System is made up of wheels and storage lanes. Hand picking is the norm for the smaller loads. The containers are placed into the storage lane from one aisle and then flow smoothly to the other side for picking, using gravity and the wheels or rollers. The lanes are slightly inclined to allow the product to slide down to the picking end.
Different Flow Types
As with Pallet Flow Rack, different roller types can be used depending on the size and type of the carton. The three most common types are Wheel Track, Full Length Roller, and Skatewheel.
- Wheel Track – The boxes are supported by 2-3 roller tracks. Typically the least expensive option, but with less flexibility. Each lane is made for one particular box size.
- Full Length Rollers – The rollers extend the entire length of the lane. A heavier duty option that provides full support for the boxes or cartons. Often used for heavier items – for example, cases of wine that need support all the way across due weight of each box. The cartons must be consistently sized.
- Skate Wheel – The most flexible carton flow option. A bed of staggered skate wheels fill an entire bay of rack and boxes of various sizes can flow straight down to the picking aisle. It can be rearranged any number of times to accommodate changing inventory. Many manufacturers offer adjustable lane dividers.
Advantages and Disadvantages
Advantages:
- Greater storage capacity
- Reduced personal movement
- Reduced amount of space used for aisles
- Next picked is always at the front of the system
- Improved productivity
- Products are always visible
Disadvantages:
- Not suitable for LIFO (last in first out) inventory
What you need to know before installing Carton Flow
If you are putting carton flow into an existing pallet rack system, you would need to measure the rack and provide the manufacturer information and specifications so that the carton flow will be compatible with the rack. Also, you would need a list of your carton sizes and maximum weights in order for someone to design the carton flow rails/decks. Carton Flow inclines with each level, so you need to make sure you have enough space at the top to accommodate that. Since the inventory is picked by hand, the system can’t go any higher than someone could reach on their own. You also need an aisle at each end, for depositing the product and then picking it. Forklifts are not needed for this system, because the boxes are hand-picked.
Carton Flow is a great high-density system when your warehouse has smaller products. It is very low energy because you don’t need to use forklifts for picking. It also utilizes space since fewer aisles are needed to access the different cartons. To find out more if this racking system is a good one for your facility, or you have any questions, contact us!
