Carton Flow Rack
High-Density Case & Split-Case Order Picking Solutions
UNARCO RACKING manufactures heavy-duty Carton Flow rack systems engineered for high-throughput distribution hubs, e-commerce fulfillment, and multi-tier pick modules worldwide.
Dura-Flex™ Carton Flow
Full-bed high-density polymer wheels providing flexible carton widths without constant lane re-profiling.
D-2 Low-Profile System
Engineered low-profile tracks that maximize vertical clearance inside existing rack shelf openings.
RhinoTrac® Carton Flow
Full-width heavy-duty aluminum or steel rollers engineered to withstand intense loading abuse and heavy totes.
RhinoDeck® Retrofit Track
Lightweight, durable carton flow lanes designed for retrofitting existing selective pallet rack step beams.
Pick Module Integration
Multi-tier picking structures seamlessly integrating gravity carton flow tracks, conveyors, and mezzanine platforms.
KPICK Welded Shelves
Rugged factory-welded carton flow shelf units offering fast installation and fixed structural track stability.
Engineered Track Details
Structural side channels with impact decks and intermediate support brackets for heavy industrial operations.
Modular UPICK Systems
Knock-down component frames offering cost-efficient export container packaging and on-site adjustability.
Product Feeds to Picking Position by Gravity Flow
Carton Flow Rack systems engineered by UNARCO RACKING optimize high-density warehouse operations by feeding products directly to the picker via inclined roller beds. By maintaining strict First-In/First-Out (FIFO) stock rotation, your order pickers are always presented with inventory at the picking aisle face while replenishment takes place safely in the rear loading aisle.
Separating the loading aisle from the retrieval aisle eliminates warehouse vehicle bottlenecks and boosts picker productivity by up to 50%. Sloped shelf profiles and knuckle-track accessories improve SKU visibility, ergonomically positioning cases and containers for rapid, strain-free piece picking.
Manufactured by RMI Industry Pioneers
UNARCO RACKING is a dedicated manufacturing member of the Rack Manufacturers Institute (RMI). Every carton flow frame and support channel is built strictly to ANSI MH16.1 specifications, providing structural integrity, certified capacity metrics, and tested seismic reliability across five global manufacturing facilities.
System Highlights & Technical Capabilities
Dura-Flex™ Continuous Wheel Beds
High-capacity polymer wheels cover the full shelf width, allowing irregular or varied carton widths to flow smoothly without lane re-spacing.
RhinoTrac® Heavy-Duty Rollers
Full-width extruded aluminum and galvanized steel rollers designed to withstand repeated shock impact in demanding distribution centers.
Drop-In & Low-Profile Flexibility
D2 Low-Profile tracks and universal beam hangers maximize vertical clear opening, increasing picking levels per bay.
Tilt Trays & Knuckle Shelves
Ergonomic front presenting angles increase carton inner visibility, speeding up split-case item picking while reducing worker reach fatigue.
Complete Single-Source Production
UNARCO RACKING manufactures both the pallet rack structural framework and the gravity flow tracks, ensuring seamless fit-up without third-party component discrepancies.
Engineering Comparison: Carton Flow Track Systems
Compare UNARCO RACKING carton flow tracks to select the ideal load capacity, wheel surface, and configuration for your distribution facility.
| Track System | Wheel / Roller Type | Standard Capacity | Carton Flexibility | Best Suited Application |
|---|---|---|---|---|
| Dura-Flex™ | High-Density Polymer Wheels | Up to 50 lbs / sq. ft. | High (Full bed accommodates multiple sizes) | Split-case picking, fluctuating box widths, e-commerce retail |
| RhinoTrac® | Full-Width Aluminum / Steel Rollers | Up to 100+ lbs / lin. ft. | Fixed or Track-guided dedicated lanes | Heavy automotive parts, industrial totes, high-abuse loading |
| D-2 Low-Profile | Polymer Wheels in Compact Frame | Up to 35 lbs / sq. ft. | High (Integrated side channel) | Tight clearance racks, multi-level mezzanines, retrofit storage |
| RhinoDeck® | Lightweight Roller Deck Sections | Up to 40 lbs / lin. ft. | Modular Lane Configurations | Economic retrofit into existing roll-formed pallet racking step beams |
| UPICK System | Snap-In Plastic / Steel Wheels | Standard Duty (Adjustable 1-1/2" pitch) | Flexible dedicated tracks | Export container knocked-down shipments, adjustable warehouse shelving |
Carton Flow Rack Questions & Answers
Consult common engineering considerations for carton flow gravity storage design and international procurement.
How does Carton Flow Rack increase order picking efficiency?
Carton flow racking utilizes gravity to transport cartons from the rear stocking aisle forward to the dedicated picking face. This physical separation of loading and replenishment from picking eliminates worker congestion and reduces total travel time by up to 75%.
What is the difference between Dura-Flex roller beds and RhinoTrac tracks?
Dura-Flex utilizes high-density continuous polymer wheel beds that allow versatile placement of cartons without reconfiguring lane dividers when packaging sizes change. RhinoTrac features full-width aluminum or steel rollers designed for rugged industrial use, heavier load capacities, and aggressive cycle picking.
Can UNARCO RACKING carton flow lanes be retrofitted into existing pallet racking?
Yes. UNARCO RACKING manufactures drop-in beds and universal hanger brackets engineered to fit standard step beams, structural channel beams, and box beams across both roll-formed and structural pallet rack frames.
What shelf pitch or angle is standard for carton flow systems?
Optimal slope typically ranges from 3/8 inch to 1/2 inch per linear foot of lane depth (approx. 3% to 4.5% grade), adjusted depending on carton bottom rigidity, weight distribution, and ambient facility temperatures.
Ready to Engineer Your Gravity Flow System?
Our engineering team designs custom carton flow and pick module solutions built to RMI specifications. Inquire today: [email protected]