Dyna-Flo Carton Flow Rack - Mallard ManufacturingDyna-Flo carton flow easily drops into new or retrofit storage rack systems to convert pallet space into high-density case, carton, or tote picking. What makes Dyna-Flo unique is the full wheel bed design that maximizes the space to allow for more SKU lanes and containers of varying sizes and shapes.

To ensure you get the most from your carton flow application, Mallard offers standard Dyna-Flo and Dyna-Flo HD which is a heavy-duty version of the system for larger load weights.

Taking a Closer Look

Cartons are fairly typical in shape, but totes designs can vary widely which can affect how well they flow. To help you choose the system to best suit your inventory, we’ve pulled together simple test videos of each system using totes with different shapes and load weights.

Tote Sizes:

  • 5” x 10.5”
  • 15” x 21.75”

Both systems are set on 3” centers. The system can be used as a push-back last-in/last-out (LIFO) set up with a single-aisle for loading and picking or as a first-in/first-out (FIFO) solution with separate load and pick aisles.

Load weights vary from 15 – 40 lbs.

Dyna-Flo In Action


Totes flow well in both the Dyna-Flo and Dyna-Flo test sample single-deep and 2-deep bay design. Depending on customer need, load weights, and capacity demand, your carton flow system can be designed to benefit your storage and picking operation.

Dyna-Flo Carton Flow - Mallard ManufacturingA cautionary note – the clear totes in this sample have a bottom lip around the edge that caused them not to flow consistently when positioned width-wise or parallel to the rows of wheels. With gravity flow rack designs it’s all about contact. The contact between the bottom of the case, carton, tote or pallet, and the wheels or rollers. In this case, the Mallard engineers found that the tote flowed better by turning it perpendicular to the wheels. However, the single-deep lane may not provide the system depth needed.

The 2-deep system works well to store more than two totes in the lane and guarantee flow. If the totes do not fit well in the shallow lane, they risk getting pushed too far back onto the rear beam. In that case, they will likely get hung up and not freely flow and they could possibly fall out of the rack damaging inventory and causing a safety concern.

Dyna-Flo & Dyna-Flo HD Features & Benefits

  • Specialized mounts make installation easy
  • Full wheel bed design maximizes space
  • Quality wheels and axel assembly go the distance
  • Rails available in 12″ & 16″ widths for best fit across most rack bays
  • Easy to install full-length and partial dividers available for fast reprofiling


Dyna-Flo Carton Flow

Dyna-Flo HD Carton Flow

Optimized Carton Flow with Custom-Fit Accessories

Mallard offers several carton flow accessories that enhance the use of your system and can provide protection from abuse and prolong the life of your rails.

Entry guides & Full-lane dividers – Choose from snap-on entry guides or full-length lane dividers to keep SKU lanes segmented and help workers more quickly and accurately identify inventory. Both products quickly install and reposition to help with reprofiling.

Impact Tray – Impact trays take the hit from repeat loading of heavy cases and totes.

Tilt Tray – Tilt trays are angled trays that improve ergonomic positioning of the inventory to help the pickers better see the product, reduce reach and strain as well as improve picking accuracy.

Easy Carton Flow Ordering

To order Dyna-Flo carton flow couldn’t be simpler. Check out our Request for Quote form on our Resources page and it will guide you through the specs we will need to design your system. If you have questions, our gravity flow rack experts are here to help! Just give us a call.

Common Dyna-Flo HD Applications

  • Wine & Spirits
  • Beverage
  • Dairy Products
  • Hardware
  • Auto Supply
  • Retail/Finished Goods Packaging