1. Pealing Back the Layers of Pallet Flow Design for Layer Picking

    Creating custom palletized orders via a layer pick system means building a pallet, one layer at a time using a layer pick forklift attachment or similar apparatus. The completed pallet is often called a “rainbow” pallet as it is made up of different layers of inventory – i.e. a unique SKU of cases per layer. Using pallet flow rack vs simple floor stacking to continually feed reserve stock fo…Read More

  2. 7 FAQs — Designing Deep-Lane Pallet Flow Using the Forklift Separator

    The forklift separator (FL-300) is a friend for deep-lane, multi-level, high-density pallet flow systems. Why do we say that? Deep-lane systems are highly efficient and productive uses of warehouse space and resources, as long as they are properly designed to accommodate for pallet back pressures... that’s where the forklift separator springs into action. Back pressure is the force of gravity in…Read More

  3. Efficiency Boosting Gravity Flow Options for Wide Ranging Totes

    Bins and totes are handy in manufacturing and warehousing for keeping small parts and pieces organized and “pick ready.” They’re made from a variety of materials and come in an array of sizes and shapes with a wide range in load capacities. Carton flow rack is the most popular gravity flow application for bins and totes; however, pallet flow rack can be configured for tote or bin application…Read More

  4. 7 FAQ’s to Ask Before Applying the CP Pallet Flow Separator

    The ever-growing consumer appetite for “more” delivered faster and cheaper is putting a strain on order picking operations. Case picking and split-case picking are the means by which most customer demands are fulfilled, but these can also be expensive, labor intensive processes with some inherent difficulties. We can help eliminate case picking challenges with smart pre-planning and our unique…Read More

  5. To Pallet Flow Rack Installation and Beyond… Save the White Envelopes!

    When you purchase a pallet flow, carton flow or gravity conveyor system system from Mallard Manufacturing, special care is given to more than the design and manufacturing of the system and components. The signature White Envelope that accompanies each Mallard order contains the “fingerprints”, if you will, for your entire system. White Envelope Contents: General installation instructions Speci…Read More

  6. Find the WOW at Mallard Booth S449 – PROMAT 2019

    The PROMAT 2019 theme is “Find Your WOW” and we couldn’t agree more! Besides our giant floating Mallard duck balloon, there will be a lot of Wow at Booth S449. Synonyms for "Wow" include Triumph, Winner, Sensation and that’s exactly what the Mallard team offers to all our customers seeking, efficient, cost-effective gravity flow material handling solutions. Our solutions are customizable, …Read More

  7. Outside the Box Thinking Leads to Inside the Box Solution

    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…Read More

  8. Significant Weight Changes Prompt a Productivity Review

    About a year ago we designed a pallet flow system for a customer who had 21 different pallets with a wide range of inventory weights, from 500 – 1100 lbs. It was a challenge, but our engineering team came through and the customer’s request was satisfied. We even blogged about the complicated test and successful outcome. Recently, a follow-up call with the customer revealed that their pallet cr…Read More

  9. Increase Access to Productivity with Pallet Jack Access Ramp

    WIP, Assembly & Staging Inventory Flow Optimized with Floor Mounted Pallet Flow Our latest 3D animated product video shines the light on the benefits of the pallet jack access ramp - a Mallard engineered application for pallet flow. The ramp is a creative, cost-efficient solution that allows a pallet jack to access floor-mounted pallet flow in work-in-process (WIP), assembly or staging operati…Read More

  10. Planning for Bottle Pick Rack Made Easy with New Spec Sheet

    Mallard’s Bottle Pick Rack improves picking efficiencies for each picks and case-building in wine & spirits order fulfillment. As opposed to storing slower moving SKUs and each picks on static rack, bottle pick rack condenses inventory and provides an orderly gravity flow solution that improves pick rates and accuracy. Bottle pick is easy to install by simply securing the individual flow lan…Read More