Pallet Flow Rack System Design for Pallet Jack Access | Mallard Manufacturing

One of the great things about gravity flow racks is that you can access them via forklifts, people (case picking), robots (layer pick and pick arms), and pallet jacks. Just like any other storage rack system, it’s critical at the design stage to know how or what will be accessing your system to ensure a safe, productive workflow. For a recent pallet flow test, we ensured that the pallets flowed consistently, at a safe speed, and were secured in the lane until the pallet jack arrived. Take a look at our process and the system accessories that make it all work so well.

Learn more about Split Roller Pallet Flow: https://mallardmfg.com/full-split-roller-pallet-flow-rack/
Contact the Mallard gravity flow experts: https://mallardmfg.com/contact-us/
Go to the complete blog: https://mallardmfg.com/pallet-jack-accessibility-flow-rack-system-safety-meet-in-this-smart-design/
Read the blog excerpt below:
Pallet Jack Accessibility & Flow Rack System Safety Meet in this Smart Design

Standard GMA-style pallets are the most common pallets and the easiest to work within a flow lane. However, there is almost always a way to configure your lane for non-standard pallet specs. In this case, the customer-supplied pallets do not have bottom cross boards. Instead, they have three narrow runners that will make contact with the lane.
Almost like threading a needle, the forklift operator loading the pallet will have to ensure that it’s centered over the rails. To help with that process, we choose 9” wide split roller rails vs. the more narrow wheeled pallet flow rails. The wider surface area gives the operator a little leeway side to side.
Your pallet construction is critical to the flow rack system design. Be sure to bookmark our Everything About the Pallet Blog for quick referrals when designing a pallet flow lane.

Testing the Pallet Flow Rack System Design

Once the team decided on split roller pallet flow, the test progressed quite simply. The inclusion of Ultra-Grip rubber-coated rollers combined with indirect mount speed controllers prevent the pallets from gaining too much speed, which can cause pallet shifting and possibly injure workers or damage inventory. Take a look...

Pallet Flow Lane Specs:
Split roller pallet flow - 3-Rails of 9” wide each
Rollers - 1/9” diameter, set on 2” centers
Indirect mounted speed controllers with Ultra-Grip rollers
Lane pitch - ⅜” per foot over 30’
Lane width 48” out-to-out
Bolt-on ramp stops

Pallet Specs:
Wood pallets with narrow runners
42"w x 46"d
Load weight - 500 lbs.
Runners - 1 ¼” wide
Flow positioning - the easy way (bottom boards parallel to the rails)
Condition - fair to poor with warping and some broken boards

Pallet Jack Access for Pallet Flow Rack

Pallet jacks are a quick, agile way to load and/or extract pallets from a pallet flow lane. You have two options for the mounting design that will allow the jack to access the pallets: 1. Floor-mounted or 2. a pallet jack access ramp.

Pallet flow mounted flush to the ground as a push-assisted system often used in dock staging and intake. Pallet flow mounted with a slight pitch, as in our example here, is loaded from the rear with a forklift and then accessed via the pallet jack access ramp to pick pallets from the opposite side.

Pallet Jack Access Ramp Features

Galvanized steel with slip-free textured surface
Customizable size and height

The Mallard team is here to help you find the right storage and material flow solution for your operation. Our design experts are great at finding new ways to configure a customized flow rack system to maximize your space and equip your team with the tools they need to succeed. Call our gravity flow rack experts today for a free consultation.

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