Whether you’re using pallet flow for high density full pallet storage or floor level case-pick applications, back pressure – the pressure exerted from the weight of the rear pallets – can have serious impact on worker safety and productivity.  Back pressure is approximately 6% of the combined weight of the rear pallet loads.


  • 5-deep system, each pallet having a 2,500 lb. load.
    Back pressure = .06 x 2,500 lbs. x 4 pallets600 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. The forklift operator can now safely extract the front pallet.

Now consider an extra-deep flow system, 20 pallets deep and multiple levels high. The back pressure is .06 x 2,500 lbs. x 19 pallets = 2,850 lbs.;  this is significant for low level order picking applications but critical at higher elevations where the fork lift mast capacity will be reduced.  A single separator isn’t enough to hold back pressure.  With our NEW dual separator design, we are able to place a 2nd separator further back in the lane, reducing the back pressure by half.


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 Flow Lanes


Call Mallard’s gravity flow specialists for more details, design advice or a free quote.

(800) 243-6694 (USA only)
(815) 624-9491
or info@mallardmfg.com