Push-Back Pallet Rack - Mallard Manufacturing

Admittedly, you’re probably wondering what we are showing you in the image above. Well, it’s a very unique push-back pallet flow solution to a very unique storage challenge. Let us explain…

A global petroleum refiner was looking for a way to efficiently store IBC (intermediate bulk storage ) containers of raw materials at multiple refineries. The tricky part was that these IBC containers had to be kept in a refrigerated/temperature-controlled space.

Push-Back Pallet Rack - Mallard ManufacturingThe Challenge:

  • Create a refrigerated storage solution for multiple IBC containers of raw materials for processing.

The Parameters:

  • Economical
  • Refrigerated
  • On-site at multiple refineries
  • Enough room for 2 weeks’ worth of inventory

Off-site, rented refrigerated space is expensive, we all know that. However, building several stand-alone storage units on-site would also be cost-prohibitive. Therefore, our out-of-the-box idea centered around using refrigerated cargo containers that would provide a cost-effective and convenient alternative.

Now to address the need for efficient storage and handling of those IBC containers.

The Gravity Flow Solution:

  • Refrigerated cargo containers – 39’deep
  • Mallard push-back pallet flow – 2 lanes wide (up to 10 pallets deep)
  • Custom floor mounts
  • Custom ramp stops

Full Roller Pallet Flow - Mallard Manufacturing

With the IBCs positioned on pallets, they are easily transported by standard forklift onto custom floor-mounted, push-back pallet flow lanes installed within each shipping container. The forklift drivers only need to place each pallet in the first pallet position as opposed to driving into and out of the shipping container. Rear pallets are gently pushed back as subsequent pallets are added and conversely, rear pallets automatically flow forward as front pallets are picked. Custom ramp stops with forklift notches are bolted on the front of the pallet flow lane to ensure the pallets remain secure within the lane until they are removed by the forklift.

Push-Back Pallet Flow - Mallard Manufacturing

We were very happy to have solved this storage challenge for our customer. Honestly, our creative gravity flow solutions surprise even us sometimes, but we are always willing to test out a new approach… whether it’s inside or outside of the box. Give us a call and let’s discuss your inventory challenges and see where our solutions can take us next.