Carton Flow Rack in Lackawanna, NY

Case flow rack selection begins with the underside of the load. Molded tote feet, bowed case bottoms and narrow bearing surfaces can change how a container rides the wheels. Sample testing helps establish the roller pattern, lane guides and slope. A heavier load also needs controlled presentation at the front so a person is not struggling to separate or withdraw it.

Lane dividers should guide the container without leaving excessive sideways movement or squeezing a changing case width. We consider handles, labels and access to the contents as well as outside dimensions. For piece picking, opening a case can change its shape or strength, so the package should be reviewed in the condition in which it will actually sit at the face.

Carton flow racking can be incorporated into a suitable pallet rack bay or planned as a dedicated picking structure. An existing frame requires a compatibility and loading review before a retrofit is selected. Whole pallet movements call for a different discussion about pallet flow; irregular metal parts and very slow lines may remain better suited to bins or shelving rather than gravity lanes.

Trace the supply route

We establish where containers arrive, where reserve stock sits and where operators consume the contents. That route shows whether a rear-loading face is practical or whether another location would reduce handling between storage and use.

Examine actual containers

Provide typical totes and cases, including opened examples where pieces are selected individually. We check their bearing surfaces and consider how empty containers return so that packaging movement is part of the proposed layout.

Allocate working lanes

We group items by handling method and replenishment needs, then set lane widths and stock depth. Levels are positioned with withdrawal weight and reach in mind, rather than giving every item an identical opening.

Prepare the work area

The agreed plan identifies the equipment footprint and access needed by experienced installation crews we schedule and manage. Feeding checks with representative loads follow placement so operating staff can confirm the intended picking and refill routine.

A Practical Basis for Manufacturing Picks

Lackawanna Lane Storage Planning

On redeveloped industrial land, the current building layout matters more than assumptions about how neighboring operations work. Record internal travel routes and staging needs before placing a pick face near receiving or production. Keep rear access clear enough for the replenishment method you intend to use.