Relieve Back Pressure in Extra-Deep Pallet Flow with Dual Separators

Extra-deep pallet flow systems can store over 20 pallets deep at multiple levels high.  Ideal for high density and fast throughput, these deep lane systems can also cause added back pressure – the force exerted from the weight of the rear pallets on the front pallet, or .06 x (pallet load weight)  x # of pallets. This is significant for lower level picking applications but even more critical at higher elevations where the fork lift mast capacity is reduced.


  • 5-deep system, 2,500 lb. load.  Back pressure = .06 x 2,500 lbs. x 4 pallets =  600 lbs.
  • 20-deep system, 2,5000 load.  Back pressure = .06 x 2,500 lbs. x 19 pallets = 2,850. lbs

The Solution – a pallet separator can be used to hold and lock the rear pallets at a comfortable distance of 6″- 12″ behind the first pallet, essentially removing all back pressure force. With our new dual separator design, a 2nd separator is placed deeper in the lane, further reducing the back pressure by half. The forklift operator can now safely extract the front pallet.

Take a look at our recent product testing video – The test lane is 6 pallets deep with dual separators located after the first and fourth pallet positions.  As the front pallet is lifted by the forklift, the front separator triggers the release of the next 3 pallets.    As these pallets come to rest, the rear separator is then triggered to release the remaining pallets; maintaining separation between pallet 1 and 2 and pallets 4 and 5, reduces excessive back pressure from these rear positions.

Advantages – Single and Dual Pallet Separators

  • Relieves the back pressure on the lift truck
  • Prevents product damage
  • Allows the pallets to safely index forward
  • Prevents restart issues
  • Easier and faster for the lift truck operator

Dual Pallet Separator Pallet Flow Rack IllustrationMore Dual Separator Illustrations