Flow racks

Flow racks are one of the four main groups of physical equipment that support the flow of materials. Although they are not as visible as the other options, which include carts and workstations, they are pivotal in the work areas where they are found. 

What Are Flow Racks?

Flow racks are also known as gravity flow racks or carton flow systems. They are dynamic shelving units that use sloped roller tracks or wheels to allow items to move forward automatically. When an item is picked from the front, the following one slides forward from behind, keeping products always available at the picking face.

Flow racks work by using gravity to eliminate the need for manual restocking at the front. The racks are particularly useful in environments where high picking frequency and space efficiency are crucial. They are used across various industries, including automotive manufacturing, food and beverage, pharmaceuticals, and e-commerce fulfilment.

LKE offers a wide range of flow racks built using high-quality aluminium or steel frames and is available in both standard and customised configurations to suit individual workflow needs.

Benefits of Flow Racks

Incorporating our range of flow racks into your operations can have different benefits, including: 

• Improved Productivity: Items automatically move to the front, reducing downtime for restocking and enhancing picking speed.
• FIFO Efficiency: Ensures that the oldest inventory is used first, maintaining product freshness and reducing waste.
• Space Optimisation: Flow racks utilise vertical and horizontal space efficiently, allowing for compact storage.
• Reduced Handling Time: Workers can access items more easily, resulting in decreased travel and loading times.
• Enhanced Ergonomics: Designed for convenient item retrieval at waist height, reducing strain and improving workplace safety.
• Versatility: Suitable for different item types, from small parts to larger boxes or bins.

These benefits make flow racks an essential component of lean manufacturing and modern logistics environments.

Types of Flow Racks Available at LKE

We offer an extensive range of flow rack systems tailored to meet the specific needs of various industries and operational requirements. Each type offers unique functionality for specific workflows, ensuring maximum efficiency in product movement and storage.

Carton Flow Racks

Carton flow racks are specifically designed for storing and handling lightweight items such as boxes, cartons, and small packages. They have inclined roller tracks that allow items to roll forward automatically as the front items are removed.

These racks are ideal for pick-and-pack stations, assembly lines, and order fulfilment centres. Carton flow racks are available in adjustable configurations to accommodate varying box sizes, making them flexible for different product ranges.

Pallet Flow Racks

Pallet flow racks are built to handle larger and heavier loads, making them ideal for warehouse and industrial environments. They work similarly to carton flow racks but are designed for full pallets instead of small boxes.

With high-load-capacity rollers and robust steel frames, these racks enable efficient FIFO stock rotation while minimising forklift movement. They are commonly used in cold storage, food distribution, and high-volume warehousing operations.

Dynamic Flow Racks for Lean Manufacturing

Dynamic flow racks are modular systems that support lean production principles. They are used at workstations or assembly lines to provide workers with a continuous supply of components.

These racks can be equipped with return lanes, roller beds, and ergonomic loading and unloading features. They are particularly popular in the automotive, electronics, and machinery industries where efficiency and precision are essential.

Customised Flow Rack Systems

Not all businesses require the same handling equipment. We also recognise that each facility has distinct storage and handling requirements. That is why we also offer customised flow racks with the help of our engineering team. Our flow rack solutions can be tailored to fit specific processes, load types, and spatial constraints.

Custom options may include adjustable lane widths, modular roller beds, braking systems, and specialised designs for integration with automated guided vehicles (AGVs) or conveyor systems.

Applications of Flow Racks

Flow racks have a wide range of applications across various sectors.

• Warehousing and Distribution: Streamline order picking and stock rotation.
• Manufacturing: Deliver components to production lines efficiently and effectively.
• Retail and E-commerce: Simplify order fulfilment and restocking.
• Food and Beverage Industry: Maintain a FIFO (First-In, First-Out) rotation to ensure product freshness and optimal quality.
• Automotive Assembly: Organise and deliver parts to workstations quickly.

Key Features of LKE Flow Racks

When selecting flow racks, it is crucial to identify the features that matter most, ensuring you choose options that are ideal for your operations and will deliver a return on investment. Some of the key features of our flow racks include:

Key features include:

• High-quality aluminium or steel frame construction
• Adjustable roller track angles for optimal flow
• Modular design for easy configuration and expansion
• Durable rollers designed for smooth, consistent movement
• Optional side guards to prevent product displacement
• Compatibility with standard bins, cartons, or pallets
• Customisation available for specific operational needs

Each flow rack system is designed to integrate seamlessly with existing logistics setups, ensuring a smooth and efficient material handling process.