Can flow levels fit below pallet reserve in our existing bays?

They may, subject to a review of the entire proposed configuration. Reserve loads, beam elevations, flow supports and picking clearances must be considered together rather than treating the lower picking levels as an isolated addition.

How do you plan around a Greenfield flex building's columns?

We place column locations and surrounding work areas on the drawing before setting module positions. Both faces need usable access, so a bay that fits between obstructions may still be unsuitable if replenishment cannot reach its rear.

Can small packaging cartons occupy neighboring lanes?

Yes, when roller support and lane clearance suit their dimensions. Dividers preserve product separation, but spacing should reflect the loaded package shape, including any bulging or projections, rather than measurements from an empty carton alone.

What if there is no workable rear replenishment aisle?

The layout needs reconsideration before specifying a conventional rear-loaded module. Reorienting the picking area or selecting another arrangement may be more appropriate than squeezing flow levels into space that cannot support the intended loading method.

Carton Flow Rack warehouse storage example

Greenfield, Wisconsin

Carton Flow Rack in Greenfield, WI

Name: Milwaukee Pallet Rack
Address: 7311 W Greenfield Ave., Milwaukee, WI, 53214, US
Telephone: (414) 260-3593
Price range: $$

Carton flow rack in Greenfield uses inclined roller lanes to move cases or totes toward a consistent front picking position. Operators replenish from the back, supporting FIFO movement when stock enters in sequence and each lane retains its assigned product. The module separates active carton picking from the deeper storage behind it.

Wholesale distribution and printing and packaging operations along the Layton Avenue corridor and Forest Home Avenue industrial area can carry many small consumable lines within limited warehouse space. Converting suitable pallet bays into picking modules may bring those cartons together, but the layout must account for columns, stairs and the actual rear loading approach.

(414) 260-3593

Carton Flow Rack Retrofit Planning and Installation

An existing bay is not automatically ready for carton flow rack inserts. We review frame and beam dimensions, connection details, support needs and proposed loads. The flow level depth and elevations must suit both the supporting structure and the container presentation required by the people picking orders.

Lane widths and dividers organize different carton sizes without allowing packages to interfere with neighboring stock. Roller spacing must support smaller bases, while inclination and the discharge arrangement are chosen for the container and task. Suitable presentation can support order picking speed by reducing searches and reaches into deep shelving.

We prepare free CAD showing the proposed module within the surrounding work area, then provide an itemized new-material quote. Experienced crews carry out installation under our scheduling and management, with the agreed access arrangements and component scope established before installation work begins.

Compare the storage choices for your operation: Greenfield warehouse planning options; Case flow module choices; Greenfield pallet flow storage; Greenfield pushback pallet layouts.

Wholesale small-case picking

Printing consumable cartons

Packaging supply order lines

Light assembly parts presentation

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Evaluate Carton Flow Rack Retrofit Choices

Compare the existing bay structure with the handling task before deciding how many flow levels belong in the module.

Locate fixed features

Mark columns, stairs and permanent work areas within the available footprint.

Record rack details

Gather bay measurements, component identification and present beam elevations.

Fit product lanes

Assign widths, dividers and roller support around loaded package dimensions.

Check both approaches

Confirm that picking and replenishment routes remain usable around the module.

Carton Flow Rack Within Existing Footprints

Our carton flow racking planning begins with the usable footprint rather than the wall-to-wall floor area. A module needs working space at both faces, plus a route for completed orders. We examine these movements before allocating lanes so additional pick positions do not merely transfer congestion into the surrounding aisles.

Operating as a division of Warehouse Equipment & Supplies Co., we have handled storage system supply and installation since 1997. We provide a substantive consultation about your building arrangement, packaging assortment and order handling, explaining where a bay retrofit makes sense and where another storage approach deserves consideration.

Bay reviews that include the proposed flow supports and loads.

Picking positions arranged around real building obstructions.

Lane dimensions matched to packaging cartons and supply totes.

Carton flow rack with gravity wheel beds and case lanes

Carton flow shelving in use on a warehouse pick line

Count Working Access Alongside Storage

Case flow rack needs more than room for steel. Show the order container beside the picking position and the replenishment load behind it. Keeping those activities visible in the drawing helps prevent a compact module from consuming the space operators need to use it.

Local distribution

Service parts

Commercial supply