Mallard offers 6 pallet flow rack products to handle every type of inventory, operational function and warehouse climate. If narrowing in on and developing the perfect lane for your need seems like a daunting task…do not fear, Mallard Best Practices is back with 8 Steps to follow to simplify the process.

Magnum Wheel Pallet Flow - Mallard Manufacturing


Steps to Designing a Pallet Flow Solution

Step 1 – Determine project scope.

Step 2 – Design pallet flow lane, test lane parameters for effectiveness.

Step 3 – Design full pallet flow rack system, develop quote.

Step 4 – Issue/Receive P.O.

Step 5 – Complete approval process.

Step 6 – Ship pallet flow rack materials and accessories to job site.

Step 7 – Install pallet flow system using qualified, rack installation team.

Step 8 – Project sign off.

Step 1 – Determine Project Scope

Begin with a thorough review of your inventory and order fulfillment needs. Are you looking for case or each pick fulfillment, high-volume case picking, high-density pallet storage or staging? Answer these key initial questions — What is the available warehouse space, warehouse climate, equipment & labor availability, inventory specs and throughput rates?

Step 2 – Design & Test the Lane

From the information gathered, develop your pallet flow lane design. Contact the Mallard team to schedule an Engineering Testing Lab pallet flow test. The test will require actual pallets, containers and in some cases sample inventory to ensure the system safely and consistently flows the materials. In some cases, pallet flow accessories such as speed controllers, entry guides and occasionally custom features are recommended by the team. Customers are supplied with a video of the test, along with a pallet evaluation which depicts deficiencies that may need to be corrected to proceed with a successful project and recommendations confirming the most suitable configuration.
Pallet Flow Rack Design - Mallard Manufacturing

Step 3 – Develop Quote

A detailed, itemized quote is developed which includes M-elevation drawings (image right) to help the customer visualize the system within the context of their warehouse or distribution center.

Step 4 – Issue Purchase Order
Step 5 – Complete Approval Process
Step 6 – Ship

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TQM Packaging

Once the Mallard team receives the purchase order, a ship date is scheduled and confirmed with the customer, and the product is readied for shipment to the job site.  The Mallard Total Quality Management (TQM) process assures that your order is carefully processed and packaged and content is verified for accuracy. The packaging is also inspected to ensure that it is wrapped, sealed and marked to our strict regulations for protecting the contents from damage while en route to the job site.

Mallard ManufacturingStep 7 – Install Pallet Flow System

The Mallard team highly recommends using experienced, qualified, pallet flow rack installers to install your system. We also provide resources to help answer questions should some arise.

Step 8 – Project Sign Off

We understand that by ordering gravity flow solutions from Mallard your expectations are very high… so are ours. As a team, we strive to not only meet customer expectations but to exceed them. We appreciate the trust customers put in our gravity flow products and designs and value our many long-term industry relationships.

Contact the Mallard gravity flow experts for design ideas and a quote on your next warehousing challenge project.