Tips for Controlling Pallet Speed in a Gravity Flow Rack System | Mallard Manufacturing

The Mallard gravity flow rack engineers take on an interesting pallet flow configuration. Lightweight loads on plastic pod pallets. Building a pallet flow lane takes a systematic approach and takes as many tries as needed to confirm that we provide the most "effective" solution to meet our customer's needs. The basic steps we follow take into consideration: pallet speed, lane pitch, stability of the load, pallet contact with the wheels or rollers, consistent flow, and restart after sitting. Here's a closer look at the process...
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Mallard Engineers Put the Brakes on Accumulating Pallet Speed

What are the essential qualities of your gravity flow rack system? Condensed and efficient storage probably top the list, and for good reason. A lot is packed into the word "efficient," however. We use it a lot, and most likely you do too because of all that it represents. In a gravity-flow system, like this full roller pallet flow lane, for example, efficient means all this and more:

What is Efficient Pallet Flow?
• Less labor required to move pallets about the warehouse
• Pallets flow without hindrance to the extraction end of the lane
• Pallets are organized by lane to facilitate accurate selection
• Pallets are always available at the pick face for extraction
• It is safe and relatively easy to extract the pallets

In general terms, our job is to help you configure the gravity flow rack that will make all this efficiency come together… day-in and day-out. This pallet flow test is hot off the presses from our in-house Engineering Testing Lab, and it's a great example of how to test a lane to find safe flow speed and pallet control. Take a look.

Pallet Flow Lane Design
• Full roller pallet flow rack – 1.9" rollers on 2" centers
• Ultra-grip roller speed controllers
• Indirect mount (FIBA) speed controllers
• Bolt-on ramp stops

Full roller pallet flow is most often our go-to for plastic pallets. There is a reduced surface area with pod pallets to make contact with the flow rack and full roller, having the most surface area, provides the best connection between the two.

Plastic Pod Pallet Load Specs
• Size: 50"w x 60"d x 84"h
• Load weights: 125 lbs. – 150 lbs.
• Loads: Styrofoam - banded and stretch wrapped
• Description: Lightweight, plastic, 9-pod pallets with small front and rear pods and larger center pods

Test, Test, and Test Again!
It took a few pallet flow lane iterations to ensure safe, consistent speed for these very lightweight and awkward pallet loads.

Test #1 - Pitch - ½" per foot with Ultra-Grip + Indirect Mount Speed Controllers
Initially, we noticed that the combination of the Ultra-Grip and indirect mount speed controllers cause the pallets to hang up. The pallets are too light for this often effective combination.

Test #2 – Pitch – 7/16" per foot with Ultra-Grip Speed Controller Only
In the second test, we remove the indirect mount speed controllers (mounted underneath the Ultra-Grip rollers) and drop the pitch to 7/16" per foot to see if the rubber surface of the Ultra-Grip will be enough to flow the pallet properly. Unfortunately, we see that the pallets pick up too much speed, which can cause them to skid over the rollers, possibly creating a safety concern.

Test #3 – Pitch – 3/8" per foot with Ultra-Grip Speed Controller Only
The third test proved out to deliver effective results. The pallets flowed consistently and at a safe rate.

Test #4 – Pitch – ½" per foot - Push-Back Flow Rack
Pallet flow is a flexible system for either First-In/First-Out (FIFO) inventory rotation or as a push-back flow system for Last-In/Last-Out (LIFO) inventory rotation. A LIFO system benefits from single-aisle access for loading and unloading, saving floor space for the proper application. The team conducted a quick test to show how easily the lane would convert and demonstrate the best lane pitch for a LIFO system should the customer decide this works better in the field.

Test #5 – Full Roller Pallet Flow on 3" Centers
As you will see as the test video concludes, the team ran one more test to confirm that the roller positioning at 2" centers was the most cost-effective design. This test proved that the pallets need more roller coverage to flow consistently and without hang-ups, so indeed the 2" centers are the best final design.

No Stone Left Unturned
The Mallard gravity flow rack experts delivered on this pallet flow lane design. We took a look at all viable options and came up with the best pallet flow configuration and a good push-back design if needed. How can we help you today? Call our team for system design advice and testing. It's time to put the power of gravity to work for you.

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