What You Need to Know About Pallet Flow Rack & Back Pressure

And How to Eliminate It with Case Pick Separator & Empty Pallet Return Lanes!

We’ve talked a lot about the growing popularity of high-density, case-pick applications using pallet flow… and we fully expect the trend to continue. These systems offer the best of both worlds for manufacturers and distributors looking to maximize space and boost order-picking productivity.  Pallet flow rack provides easily accessible, dense reserve storage located directly behind the pick line.

Cases are picked from the front pallet position to the conveyor. The empty pallet is removed as the next pallet in the line flows forward to the picking position. Full pallets are replenished in the opposite forklift aisle, eliminating contention between order picking and replenishment functions.

This is a great solution with one relatively ‘heavy’ glitch; the pitch of a pallet flow rack lane adds back pressure onto the front pallet position. This pitch is what makes gravity flow… however, it can also require extra exertion to remove the empty pallet (after cases are picked) from the weight forces of the loaded rear pallets.  This “back pressure” is approximately 6% of the combined weight of the rear pallets.

Example: 5-deep system with 2,500 lb. loads
Back pressure = .06 x 2,500 lbs. x 4 pallets = 600 lbs.

The Back-Saving Pallet Separator at Work

There is an easy, affordable solution to the problem – Mallard’s Pallet Separator.  This pallet separator holds and locks back all rear pallets at a comfortable 6″- 12″ distance behind the first pallet, removing all forces.  The order selector can safely remove the empty pallet. Once back in order picking position, he or she can lift the manual pallet release latch to gently flow the 2nd pallet into position.  All remaining pallets are again locked in place behind until engaged for release.

Pallet Separator Advantages

• Reduce repetitive motion and back injuries
• Allow operators to remove pallets manually without added back pressure
• Prevents injuries caused by having to force or kick rear pallets back
• Saves on insurance by reducing workers’ compensation claims

Design Considerations

• Allow an additional 6″-12″ lane length for the separator and gap

Easy Pallet Return Video

Another Labor Saver – Mallard’s Empty Pallet Return Lanes

Efficient handling of empty pallets in a case-pick application ensures the workspace remains productive, organized, and safe. Reverse flow lanes, strategically placed along the pick aisle, are used to stack empty pallets and return them to the forklift aisle.  Mallard’s empty pallet return allows for up to 10 stacked empty pallets. Using a simple handle lever, the empty pallet stack is released and gradually flowed toward the forklift aisle for removal.

Empty Pallet Return Advantages

• Separation of fulfillment and forklift operations
• Reduced travel time for carrying empty pallets
• Reduced worker back injuries
• Increased productivity. Call Mallard’s gravity flow specialists for more details, design advice, or a free quote.