Dual Pallet Separator for Pallet Flow - Mallard Manufacturing

There’s already enough pressure in high-throughput warehousing operations… your pallet flow rack system shouldn’t add to it. As a matter of fact, with Mallard’s dual pallet separators you’ll actually remove pressure inherent in deep-lane pallet flow systems and help to improve efficiency and safety.

Dual Pallet Separator for Pallet Flow - Mallard ManufacturingOur dual pallet separators are uniquely designed to work in deep-lane and extra-deep systems (20+). They release and re-engage precisely at the right moments of pallet flow.

Dual pallet separators increase the safety and effectiveness of deep-lane pallet flow by reducing the back pressure inherent in the pitched lane design of a gravity flow system. Back pressure is term used to refer to the force exerted from the weight of the rear pallets onto the front pallet.

Calculating Back Pressure

Multiply the combined weight of the rear pallets by .06, i.e. for a 10-deep flow system with 2,500 lb. loads = .06 x 2,500 lbs. x 9 pallets or 1350 lbs. of extra pressure.

For a 20-deep system with 2,500 lb. pallet loads =.06 x 2,500 lbs. x 19 pallets = 2,850 lbs. additional pressure.

Here are some of the most frequently asked questions regarding the dual pallet separators… and the answers that will help you decide if this application is best for your organizational needs.


7 FAQs – Dual Pallet Separator for Pallet Flow

  1. Does my pallet flow operation require Dual Pallet Separators?

Dual Pallet Separator for Pallet Flow - Mallard ManufacturingMallard’s dual pallet separator is designed for deep-lane and extra-deep systems (up to 20 pallets) where the impact of back pressure is most critical. Using two separators – one positioned behind the first pallet, and a 2nd placed deeper in the lane– the back pressure is further reduced. The isolated front pallet is quickly, easily and safely removed by the forklift operator which is critically important in higher elevations.

  1. How do the Dual Pallet Separators operate?

The dual pallet separators are designed to be trouble free and to work in tandem in deep-lane and extra-deep lane pallet flow systems. The separators automatically disengage once the front pallet position is clear to trigger the release of the rear pallets to advance down the lane. Once the front pallet position is filled, the separators reengage to lock the rear pallets in place.

  1. How are the rear pallets released?

Dual Pallet Separator for Pallet Flow - Mallard ManufacturingWhen the forklift operator lifts the front pallet out of the lane, the separators automatically disengage and allow the rear pallets to advance down the lane. Once the front pallet position is filled, the separators reengage to lock the rear pallets in place

  1. What is the recommended lane depth of a pallet flow lane equipped with Dual Pallet Separators?

Our dual pallet separators are designed to work in deep-lane and extra-deep systems (20+). Depending on pallet weights will help determine if the dual pallet separator is needed in lanes less than 10 pallets deep.

  1. What pallet flow rack options are available for use with the Dual Pallet Separator?

The dual pallet separators can be used with all Mallard pallet flow rail products: Magnum wheel, steel skate wheel and roller systems.  For roller applications, split rail is used at the charge and discharge ends… full roller can be used in the middle of the lane.

  1. How do I properly design my pallet flow lane to include the Dual Pallet Separator?

Dual pallet separators are ideal for deep-lane and extra-deep flow systems with a 30,000 lbs. max per lane and up to 20 pallets deep. Speed controllers are also applied to the lane and the lane should be used for full pallet in/out – not case picking operations. Also plan for an additional 24” to overall depth of the system. Full-surface captive (slave) pallets should also be used.

  1. Are there additional lane accessories recommended for use with the Dual Pallet Separator?

Pallet Flow Ramp Stops - Mallard Manufacturing

As  noted above, the deep-lane pallet flow system should be equipped with speed controllers to regulate the flow of the pallets down lane, but we also recommend the use of ramp stops at the end of the lane. Ramp stops provide an extra measure of security for holding the pallet in place until the forklift removes it from the lane. Mallard ramp stops are bolted onto the pallet flow rails (as opposed to welded) so that they can be easily replaced if damaged without replacing the entire rail… minimizing downtime and expense.


Dual Pallet Separator (DS 600) Advantages:

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

Did We Answer All of Your Questions?

Our gravity flow specialists are available to explore the best options with you to ensure that the solution you choose will be right for your unique application. Call today and let’s get to work meeting your operational goals.