Pallet Flow Racking

Pallet Flow Racking is a high-density storage system where pallets are stored on rollers or roller conveyor systems. The pallets are loaded at the rear of the system onto the rollers, and driven by gravity, are conveyed down to the front of the system for easy unloading. The system is designed to have a decline slope from back to front, and a braking system is used to control the speed of the load’s decent to the front.

These systems are typically designed from 2to 15 pallets deep, but can be constructed much deeper if warranted.

The forklift aisles run perpendicular to the front and rear of the system to assist in the loading and unloading processes.


Pallet Flow Racking


  • Selectivity – Unlike Drive In racking, each level of the system provides storage for a different SKU and therefore it provides more pick faces and greater selectivity. SKU’s within each level should be consistent.
  • Inventory Rotation – The system is designed to provide FIFO inventory rotation.
  • Density – This is a high density storage system and can be designed with very deep lanes, however the incline required for the conveyor may result in fewer levels compared to Drive In racking, depending on the ceiling height and the depth of the system..
  • Damages – Forklifts do not have to enter the rack, so there is less opportunity for damages.


  • Investment – Pallet Flow racking is more expensive then Drive In racking per pallet position.
  • Honeycombing – As stock is partially depleted from a particular level pallet positions are left open, creating the honeycomb effect. These positions will remain open until new product is received. Usually operators will want to deplete an entire lane prior to receiving new product into the lane to ensure the stock is rotated. If new product is received into the forward positions, then the older product will not be rotated out of inventory. The Pallet Flow System typically less honeycombing than with a Drive-In system.
  • Flexibility – The systems are designed and engineered for particular load dimensions and weights. Reconfiguration, while possible, can be time consuming and expensive.

Best Suited For – Moderate Mix, High volume SKU’s

PalletFlow Comparison Chart

Layout and Equipment Considerations

Material Handling Equipment – Standard forklifts and reach trucks can be used. With heavy loads or deep configurations the equipment can sustain additional wear and tear.


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