Carton Flow Racking
Carton flow racking is gravity-fed case picking: load from the rear aisle, pick from the front, FIFO by design. SJF says incorporates gravity rollers right into the rack shelf itself. MH-USA says Pick rates increase 2–3× compared to static shelving. Interlake Mecalux says Carton Flow Racks separate picking and stocking tasks into different aisles.
Last updated: September 2, 2026
Carton flow racking
| Claim | Value | Source |
|---|---|---|
| Definition (SJF) | incorporates gravity rollers right into the rack shelf itself | SJF |
| FIFO (SJF) | Carton flow provides FIFO (First In, First Out) inventory control and is used in for a wide range of products. | SJF |
| Decline pitch (SJF) | The rack shelves are set with a decline pitch to allow gravity to flow from the in feed side (rear) to the pick side (front) | SJF |
| Definition (MH-USA) | Tilted roller or wheel-bed lanes installed inside pallet rack bays that use gravity to move cartons, cases, and totes from the loading side to the picking face | MH-USA |
| Lead (MH-USA) | Gravity-fed roller or wheel lanes built into pallet rack bays for organized, FIFO case and carton picking | MH-USA |
| Load/pick (MH-USA) | Load from the back, pick from the front | MH-USA |
| Pick-rate lift (MH-USA) | Pick rates increase 2–3× compared to static shelving | MH-USA |
| Pick-rate FAQ (MH-USA) | Most operations see 2–3× improvement in picks per hour compared to static shelving | MH-USA |
| Lane depth typical (MH-USA) | 4 to 8+ cartons per lane typical | MH-USA |
| Lane depth FAQ (MH-USA) | Typically 4 to 8 cartons deep per lane | MH-USA |
| SKU depth (MH-USA) | Each lane holds 3–8 cartons of the same SKU | MH-USA |
| Density note (MH-USA) | 3–8 deep per lane | MH-USA |
| Carton weight range (MH-USA) | 5 to 75+ lbs per carton | MH-USA |
| Wheel-bed weight (MH-USA) | Handles light to medium cartons (5–50 lbs) | MH-USA |
| Roller weight (MH-USA) | Handles heavier loads (up to 75+ lbs per carton) | MH-USA |
| Incline (MH-USA) | 3° to 5° typical | MH-USA |
| Levels (MH-USA) | 2 to 6+ flow levels per bay | MH-USA |
| Power (MH-USA) | None — 100% gravity powered | MH-USA |
| Retrofit (MH-USA) | carton flow tracks are designed to drop into standard pallet rack bays | MH-USA |
| Skatewheel $/lane (MH-USA) | Skatewheel lanes are most economical ($50–$150/lane) | MH-USA |
| Walk cut (MH-USA) | Some operations cut walking time by 50–70% vs. static shelving | MH-USA |
| Static pick rate (MH-USA) | 60–100 lines/hr | MH-USA |
| Flow pick rate (MH-USA) | 150–300+ lines/hr | MH-USA |
| Separate aisles (Interlake) | Carton Flow Racks separate picking and stocking tasks into different aisles | Interlake Mecalux |
| Labor save (Interlake) | save up to 75 percent of labor costs compared to a static storage solution | Interlake Mecalux |
| Platforms (Interlake) | Inclined wheel and roller platforms | Interlake Mecalux |
| FIFO (Interlake) | Perfect product rotation (FIFO system) | Interlake Mecalux |
| Box FIFO (Interlake) | First-in/First-out (FIFO) box flows | Interlake Mecalux |
| Clipless (Interlake) | Clipless tracks and guide system | Interlake Mecalux |
| Alias (Dexion) | Carton Flow Racking, also known as Carton Live Storage | Dexion |
| Load/pick (Dexion) | goods are loaded at the rear and picked from the front | Dexion |
| Beds (Dexion) | gravity-fed roller beds or wheels | Dexion |
| FIFO (Dexion) | First-In-First-Out (FIFO) inventory system | Dexion |
| Retrofit (Dexion) | Carton Flow beds can be retrofitted into existing pallet racking systems | Dexion |
| Travel (Dexion) | reduce picker travel time | Dexion |
| Track step (Dexion PU) | The width of the tracks can be adjusted in steps of 11.5mm | Dexion |
| Wheel tracks (Dexion PU) | Wheel tracks manufactured in galvanized steel | Dexion |
| Rollers (Dexion PU) | Rollers are high quality polyethylene | Dexion |
| Fed/retrieved (CSSYES) | cartons are fed from one side, and retrieved from the other | C&SS / cssyes |
| Rails/wheels (CSSYES) | combination of rails and wheels | C&SS / cssyes |
| FIFO (CSSYES) | First In First Out (FIFO) system | C&SS / cssyes |
| Gravity face (CSSYES) | Utilizes gravity to bring product to the face of the picking aisle | C&SS / cssyes |
| Travel (CSSYES) | Increases picking productivity by minimizing forklift travel distance | C&SS / cssyes |
| Density (CSSYES) | Provides high density storage for product sensitive to First In First Out rotation | C&SS / cssyes |
| Contact (UNEX) | Shelf Track carton flow systems provide up to 300% more product contact than plastic wheel rails | UNEX |
| Throughput (UNEX) | UNEX carton flow solutions increase throughput by up to 150% compared to picking from pallets | UNEX |
| Warranty (UNEX) | industry-leading 7-year warranty | UNEX |
| Definition (IMH) | Carton Flow Racking is a dynamic, gravity-fed storage system designed to improve efficiency in order picking and inventory rotation | IMH |
| Flow forward (IMH) | By using inclined roller or wheel beds, cartons automatically flow forward to the pick face | IMH |
| Retrofit (IMH) | Yes carton flow beds can often be retrofitted into standard pallet racking frames | IMH |
How carton flow works
SJF says incorporates gravity rollers right into the rack shelf itself and The rack shelves are set with a decline pitch to allow gravity to flow from the in feed side (rear) to the pick side (front). MH-USA lists Load from the back, pick from the front and None — 100% gravity powered. Interlake Mecalux says Inclined wheel and roller platforms and Carton Flow Racks separate picking and stocking tasks into different aisles. CSSYES says cartons are fed from one side, and retrieved from the other.
Depth, weight, incline, and published pick rates
MH-USA lists 4 to 8+ cartons per lane typical, 5 to 75+ lbs per carton, and 3° to 5° typical incline. MH-USA says Pick rates increase 2–3× compared to static shelving with comparison cells 60–100 lines/hr versus 150–300+ lines/hr. Interlake Mecalux says save up to 75 percent of labor costs compared to a static storage solution. UNEX says UNEX carton flow solutions increase throughput by up to 150% compared to picking from pallets. MH-USA says Skatewheel lanes are most economical ($50–$150/lane).
Sources (fetched 2 Sep 2026): SJF — What is carton flow rack; MH-USA — carton flow; Interlake Mecalux — carton flow racks; Dexion — carton flow; Dexion — carton flow picking unit; C&SS — carton flow rack systems; UNEX — carton flow; IMH — carton flow racking.
Frequently Asked Questions
What is carton flow racking?
SJF says incorporates gravity rollers right into the rack shelf itself and Carton flow provides FIFO (First In, First Out) inventory control and is used in for a wide range of products. MH-USA lists Tilted roller or wheel-bed lanes installed inside pallet rack bays that use gravity to move cartons, cases, and totes from the loading side to the picking face. IMH says Carton Flow Racking is a dynamic, gravity-fed storage system designed to improve efficiency in order picking and inventory rotation.
How deep and wide are carton flow lanes?
MH-USA lists 4 to 8+ cartons per lane typical and Typically 4 to 8 cartons deep per lane and Each lane holds 3–8 cartons of the same SKU. MH-USA lists 5 to 75+ lbs per carton and Handles light to medium cartons (5–50 lbs). Dexion says The width of the tracks can be adjusted in steps of 11.5mm.
Does carton flow require power?
MH-USA lists None — 100% gravity powered and 3° to 5° typical. UNEX says Gravity! The most powerful (and free) force in the universe. CSSYES says Utilizes gravity to bring product to the face of the picking aisle. Dexion lists gravity-fed roller beds or wheels.
Can carton flow drop into existing pallet rack?
MH-USA says carton flow tracks are designed to drop into standard pallet rack bays. Dexion says Carton Flow beds can be retrofitted into existing pallet racking systems. IMH says Yes carton flow beds can often be retrofitted into standard pallet racking frames. UNEX says SpanTrack and Shelf Track’s patented design easily drops into existing.