Ramp Up Dock Staging & Intake - Pallet Jack Access Ramp for Pallet Flow Rack

A lot of action takes place in the dock area. Intake and staging are literally the beginning and the end of efficiency, so it’s important to give your team the tools they need to get the job done. The pallet jack access ramp and full roller pallet separator combination may just be the right tools for you. If you’re using pallet jacks to hustle pallets in or out of the dock area, this is a productivity booster you’ll want to see.
To learn more about pallet jack access ramps: https://mallardmfg.com/engineered-applications/pallet-jack-access-ramp-for-pallet-flow/
To learn more about pallet separators: https://mallardmfg.com/engineered-applications/pallet-separators/flex-separator-fs-200-series/
To learn more about roller pallet flow rack: https://mallardmfg.com/full-split-roller-pallet-flow-rack/
Contact the Mallard gravity flow rack experts: https://mallardmfg.com/contact-us/
Go to the complete blog: https://mallardmfg.com/ramp-up-dock-staging-intake-pallet-jack-access-ramp-for-pallet-flow-rack/
Read the blog excerpt below:

Roller Pallet Rack Put to the Test

A major e-commerce distributor needed a make-sense solution for minimizing dock traffic while allowing pallet jack access and improving processing productivity… a tall order, yes, but not too difficult for our in-house Engineering Testing Lab. Take a look:
System Components
• Split-roller pallet flow – 1.9” rollers
• Full roller pallet flow – 1.9” rollers
• Drum roller speed controllers – 2.5” rollers
• Pallet jack access ramp
• Full roller Flex Separator (FRFS 202)
• Bolt-on ramp stops
Pallet Specs
Load weights – 470 – 2500 lbs.
• Plastic pod – 2 styles, 39” w x 47” d
• GMA-style wood - 40” w x 48” d
• CHEP wood - 40” w x 48” d

Pallet Flow Lane Design
The lane is designed with split-roller pallet flow at both the load and discharge ends. Pallets are loaded by forklift and then extracted by pallet jack. The split-roller at the load end helps properly position the pallet in the lane in order that it will be accurately positioned to flow onto the split roller rails at the end. Full roller pallet flow is positioned between the split-roller to ensure maximum contact and control the flow of the different styles of pallets. An added bonus is that it also creates a more cost-effective lane construction. Within the full roller we have installed drum roller speed controllers at regular intervals to slow the pallets and help with the pallet positioning in the lane.
Where the full roller ends, the full roller flex separator is installed to isolate the front pallet and remove back pressure from the rear pallets. The flex separator easily releases with a foot pedal and the pallet flows onto the split roller portion of the lane while simultaneously holding back the advancing rear pallets. Bolt-on ramp stops keep the discharge pallet in position until extracted by the pallet jack.

Overcoming Design Challenges
• 4 Very Different Pallet Styles
• Large Load Weight Variance
Fitting a single pallet flow lane to four different styles of pallets is a design challenge. In this example, we have two styles of plastic pallets with pod feet and two wooden pallets with different bottom configurations. Plastic pallets with pod feet are more successful in roller flow lanes but they can skid over the surface if not carefully controlled. However, too much speed control can also hold up the lighter weight pallets, so it is a delicate balance between lane pitch, speed controller design and placement that is critical to make this type of system work.

Again, the full rollers in the center of the lane provide good pallet contact and the drum roller speed controllers have just the right amount of slowing power to control the pallet tracking and prevent surfing without stopping the lighter-weight pallets so that they hang up in the lane.

Nothing is Impossible with the Right Tools
By taking a step-by-step approach we delivered a pallet flow rack system that will produce a productive result for this busy distribution center. How can the Mallard team help you today? We are ready to apply our creativity and full spectrum of gravity flow products and engineered solutions to help you meet your operational goals. Contact us to get started.

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