Maintaining productivity is one of the top goals of any warehouse, so it's important to choose a rack storage system that keeps your warehouse flowing smoothly and efficiently. Although there are plenty of rack storage options to choose from, gravity flow pallet racks stand out thanks to a variety of unique features that make your operations easier to manage. The following takes an in-depth look at the gravity flow pallet racking system and how it can meet your warehouse's unique inventory management needs.
How Gravity Flow Pallet Racking Works
Gravity flow pallet racks utilize a standard pallet rack frame as its core structure but with a few important modifications. Instead of a static racking system that requires material handling equipment to reach into the rack structure, these pallet racks utilize a dynamic system that takes advantage of gravity to move pallets into position for later picking.
What makes the gravity flow pallet rack stand out from other racks is the slight downward incline and the roller system used to aid pallet movement. Pallets are loaded via forklift from the rear of the rack storage system. The incline helps propel pallets towards the front of the rack, where material handling vehicles can quickly pick the pallet later on.
The incline can be built or adjusted at various angles to accommodate different warehouse storage needs. For example, a steep incline can accommodate warehouses where speed and ease of access are primary concerns. Steep inclines often require built-in braking systems to slow pallets as they near the end of their journey.
Flow Rack Benefits and Caveats
The inline nature of the gravity flow pallet rack system makes it easy to eliminate excess aisles, making the entire rack storage system compact. This can be a major advantage for smaller warehouses where space utilization is paramount. These rack storage systems also lend themselves well to the "First In, First Out" (FIFO) inventory management method, allowing for faster product turnover and improved inventory control.
Gravity flow pallet racks can even facilitate effective energy-saving methods in the warehouse environment. For instance, a lengthy gravity flow pallet rack system only requires the loading and receiving ends to be illuminated, allowing any lights above the middle of the rack to be turned off to conserve energy and lower electricity costs.
As with any other type of pallet rack system, there are a few disadvantages associated with the gravity flow system. For starters, the FIFO system of a typical gravity flow pallet rack limits the diversity of SKUs in each lane. Gravity flow pallet rack systems also require more maintenance than other rack storage systems due to the sheer number of moving parts involved. The wheels and brakes all require periodic maintenance and inspection, resulting in an increase in downtime as well as higher maintenance costs. These systems are also not as tolerant of poor-quality pallets as other rack storage systems.
Is It Right for Your Warehouse?
If your warehouse regularly handles date-sensitive or high-volume materials with high turnarounds, it may be able to benefit from the addition of a gravity flow pallet racking system. However, warehouses with slower inventory turnover or highly diverse product storage may be better off utilizing other rack storage systems.
There are also a few things to keep in mind when studying gravity flow rack storage systems. Height is an important consideration, since gravity flow pallet racks require enough space to accommodate the slight incline required on all levels. There should also be space at each end of the rack for material handling vehicles to load and pick pallets.
It's important to weigh the pros and cons of any rack storage system before settling on your final choice. Through in-depth research, you'll be able to make the best choice for your warehouse.
