Flo-Guide Carton Flow - Mallard Manufacturing
Flo-Guide Carton Flow

Pick, pack and ship from totes and bins has increased in popularity as fulfillment operations have adjusted to consumer demand for smaller, more individualized purchases. E-commerce has set the bar. What we can do is equip your operation with the best warehouse storage and fulfillment tools to help you measure up and succeed.

Carton flow rack is designed to be an efficient gravity flow solution for cases, cartons, totes, bins and even individual inventory items. Carton flow works most efficiently with flat-bottomed surfaces that can easily glide over the rollers or wheels. Totes can be more challenging for typical carton flow due to the presence of edges or feet on the bottom. However, the Mallard team can typically find a solution to meet your carton flow and tote need. Here are some of the parameters we look at to design an optimized carton flow solution for your tote storage operation:

Carton Flow Design for Tote Storage

Tote or Bin Specs

  • Size, shape & loaded weight
  • Bottom formation – flat, uneven, footed
  • Tote features – protruding lip or rims, etc.
  • Tote composition (plastic, metal, magnetized, etc.)

Pallet Rack Specs

The Mallard team will choose the best carton flow mounting and set-up to maximize your system capability and ensure long-term use.

Carton Flow Rack Options for Tote Storage


Cart-Trak and Cart-Trak with bearing rollers is a highly-productive carton flow solution for tote storage with a single, consistent tote. Cart-Trak’s full-width roller is a heavy-duty, abuse-resistant system providing full carton coverage and superior flow for cartons or totes of consistent size. Cart-Trak is galvanized and designed to easily drop into existing pallet rack. It is durable for the demands of heavy loads and yet, the full carton coverage is often exactly what is needed in lightweight applications.

Cart-Trak Carton Flow - Mallard Manufacturing

Cart-Trak is now available with bearing rollers. The bearings offer several benefits over standard bushings including:

  • Less Pitch – Frees up more vertical space to:

      • Accommodate more carton flow levels
      • Increase number of SKU facings
  • Fewer Rollers – bearing rollers can often be spaced further apart saving on overall system costs
  • Increased Efficiency – smooth, consistent and faster flow with fewer hang-ups

Cart-Trak is available in 6″, 9″, 12″ and 16″ widths to fit your tote and maximize storage rack space.


Dyna-Flo and Dyna-Flo HD are popular wheel-based carton flow products that are ideal for operations relying on a variety of tote sizes and even shapes. Dyna-Flo HD is a more durable choice for heavy inventory with a rating of 50 lb. sq. ft. capacity per 8 ft. unsupported length.

Dyna-Flo’s durable, full-bed design of staggered polypropylene wheels allows for consistent wheel coverage no matter what size or shape your inventory takes. It is the perfect option for product mixes with multiple and/or varying SKUs. Available in 12″ to 16″ sections, it is designed to quickly and easily drop into existing pallet rack to create a productive flow system.

Dyna-Flo Carton Flow - Mallard Manufacturing
Dyna-Flo Carton Flow with Tilt Tray


Flo-Guide Carton Flow - Mallard Manufacturing
Flo-Guide Carton Flow

Flo-Guide carton flow provides full-lane guidance for cartons, cases and totes from charge to discharge. The wheels are designed to cradle inventory as it flows in the lane and relies less on consistent contact with the bottom of the case, carton or tote. Thus, Flo-Guide is a good option for totes with a rimmed or footed bottom surface. Another benefit is that Flo-Guide doesn’t need lane guides even in a deep lane system.

Flo-Guide carton flow can accommodate light-duty (under 40 lb. loads) or heavy-duty (greater than 40 lb. loads) applications. Flo-Guide can be configured to accommodate fragile inventory or totes filled with auto parts with the same consistency and dependability.

Your carton flow system can be installed as part of a pick module to maximize storage space and pick rate and reduce picker travel and labor costs. The Mallard team will help you find the right systems paring for your picking operation and once we’ve done that… it’s off to the testing lab!

Take the Tote Test

The Mallard Engineering Testing Lab is equipped to test your carton flow design with your actual totes and inventory or inventory simulation to ensure the system will work as efficiently as possible and meet your needs. The test is a complimentary, value-added feature that we offer to our customers. Contact the Mallard gravity flow experts to discuss carton flow design ideas and to schedule a system test.