Push-Back Pallet Flow - Mallard Manufacturing
We might get some push back on this, but inventory doesn’t have to first flow down in pallet flow rack. Pallet flow is also a very effective storage solution when used as a push-back lane… and we’ve got just the test to prove our point.

The Mallard Testing Lab constructed this effective test to demonstrate the benefits of a deep-lane, push-back pallet flow solution for these large pallets of A-frame racks used in transporting panes of glass.

Benefits of Push-Back Flow Lane vs. Bulk Floor Storage

  • Safely store inventory up and off the warehouse floor.
  • Condense storage space and open-up warehouse footprint.
  • Protect inventory from damage.

Watch the Test

Push-Back Pallet Flow Rack - Mallard ManufacturingPush-Back Pallet Flow Test Parameters

  • 4-rail poly wheel lane
  • Wheel Diameter: 2.9″
  • Wheel Centers: 2″/2″/2″/2″
  • Pitch: ½” per foot
  • Rail Spacing: 79” out to out
  • Load Weight: 175-225 lbs.

How’d They Do That?

The configuration of a push-back pallet flow lane isn’t all that different from a standard flow lane in that the style of pallet and load weight dictate the type of flow rails and accessories needed.

In this test, 4-rails of 2.9” polycarbonate wheels were used and set 79” out to out to provide the best surface to wheel coverage needed to flow all the pallets in a consistent and controlled manner.

Pallet Dimensions

In all we tested 16 total pallets that varied between 6 different sizes. However, the pallet shape was similar enough to construct one pallet flow lane to accommodate the full-range of pallets.

Overall, the pallets were constructed with 2 cross boards on each side with a gap between 30” – 34.5”. The cross board sizes varied as well so the flow rails were placed strategically so that they would make direct contact with the cross boards no matter which pallet was in the system.

The A-frame racks are empty which makes these pallets rather light-weight. Therefore, speed controllers were not needed in the lane to control the flow as the pallets flow forward for discharge. The only pallet flow accessory added to the lane design is the bolt-on ramp stop that ensures the pallets remain in place until removed by forklift. Our bolt-on design enables just the ramp stop to be replaced should it get damaged vs. replacing the entire pallet flow rail.

Why Gravity Flow Rack vs. Traditional Cart Systems?

Push-Back Pallet Flow Rack - Mallard Manufacturing
4-Rail Push-Back Pallet Flow Rack

Mallard push-back pallet rack takes all the advantages of pallet flow rack and combines the condensed footprint of push-back rack to deliver a unique high-density, low-profile, dynamic LIFO storage solution.

For high-density storage push-back pallet flow is the answer. Traditional push-back cart systems max-out at 5-6 pallets deep, but our push-back systems use heavy-duty pallet flow rails that require less vertical height for multiple-deep applications, so our system can go very deep lane.

Additionally, a push-back system designed using pallet flow rails/rollers can be customized to fit non-standard-sized pallets like the ones tested in this application.

Lastly, should your inventory requirements change, a push-back pallet flow system easily converts to FIFO storage if needed.

How Can the Mallard Team Help?

If you’re facing warehouse storage challenges having to do with unusually shaped, sized, and weights of inventory, give our gravity flow experts a call. We are here to help you find the solution that best fits your needs.