The Ins And Outs of Flow Racks

Flow racks are an ideal high-density racking system since using them brings all the storage advantages mentioned in other rack systems. It is a straightforward system. Each level of each lane is used for a single SKU and has a strip of slightly inclined rollers. The pallets are placed on one side of the strip and gravity moves them over the rollers until they reach the other end of the strip (which is why they are also called gravity systems). The goods are removed from this far side. The forklifts do not have to move inside the lanes.

With this method, the first pallet that enters the level is the first to exit (FIFO system), which makes for perfect product rotation.

Why should you use flow racks in your manufacturing facility?

The first reason for using flow racks within your facility is because they encourage better ergonomics. Empty containers can be removed from each rack when they are finished and because of gravity, they will automatically be replaced by a full container waiting behind. Using, this type of system always keeps full materials at the front of the rack in the picking area for the operators. This greatly reduces the need for operators to reach and stretch for new materials, drastically improving ergonomics.

The next main reason for using flow racks is because it encourages FIFO (First in, First out) which can be seen as an inventory control method. It is quite straight forward but it means the first materials places on the flow rack will be the first materials taken by operators from the flow rack. This ensures the older materials or stock on the flow racks will be ensured to be used first and as you continue to replenish the flow rack the older goods to be on the rack will be first up to be used by the operator.

The final benefit of using flow racks is that it can help visually organize your containers and boxes as well as providing efficient storage. So when flow racks are implemented along the assembly line it can be used as a visual organization tool, color coding different containers and shelves so the operators know exactly where to pick every time.

Flow rack advantages

Flow racks offer a variety of benefits that make them an attractive option for many types of warehouse operations. Here are some of the most notable benefits:

1.Efficiency and space optimization

Flow racks are known for their high efficiency and optimal use of space. They allow for high fill levels and improved space utilization compared to traditional racking systems. As the goods are moved by gravity, many aisles are eliminated, resulting in more compact block storage and increased storage capacity.

2.First-In-First-Out (FIFO) goods movement

Another key advantage of flow racks is the ability to implement the FIFO principle. This principle means that the goods stored first are also the first to be removed. This is particularly advantageous for goods with a limited shelf life, such as food or medicines.

3.Minimized goods turnover

Flow racks significantly reduce goods turnover, as the goods roll directly from the entrance to the exit of the rack. This minimizes the likelihood of errors and damage that can occur due to the frequent transfer of goods. It also improves the material flow, as the “First-In-First-Out” (FIFO) principle is guaranteed.

Concluding thoughts

Flow racks play an essential role in warehouse logistics. They not only enable the efficient storage and movement of goods, but also support the fast picking and packing of orders. This leads to improved customer satisfaction and increased operational efficiency. Therefore, investing in a well-designed flow rack system is a worthwhile decision for any company looking to optimize its warehouse logistics.