Carton Flow Rack Systems in Greater Indianapolis

Carton flow rack is built for the picker, not the pallet. Cases sit on inclined wheel beds, so every time a picker takes one, the next slides forward to the exact same spot - a consistent pick face with less reaching into the bay. Restocking happens from a separate back aisle, so replenishment can stay separate from the pick line. For Indianapolis fulfillment teams, a full pallet reserve area does not solve a scattered case-picking problem. Around the airport logistics corridor, cartons may need to reach packing quickly while replenishment continues behind the pick face. We review picks per SKU, case dimensions, and the replenishment schedule before deciding how much lane space each item needs.

It's the right system when picking is by the case or the each, not the pallet, and when enough SKUs need a dedicated face that static shelving turns into a maintenance problem. Most warehouses run it in the lower levels of a bay with reserve pallets stacked above, so one footprint handles both active picking and overflow storage.

We size wheel beds and lane widths to your case dimensions, pick rate, and SKU count, and show where the fastest movers should sit in the bay.

Indianapolis connects I-65, I-69, I-70, and I-74, but good interstate access does not fix an internal storage bottleneck. Park 100 distribution buildings and older industrial space near Speedway need different row arrangements. We use the floor plan you provide to separate reserve storage from daily working space, rather than treating every building inside the loop as an open shell. The decision is made from load dimensions, receiving patterns, and the equipment actually operating in the building.

For this carton flow rack project, the specific task is to provide rear replenishment access and keep active case lanes near packing. We count active pick faces rather than claiming carton flow creates pallet positions. Full-width wheel beds and separated tracks suit different carton profiles, and travel needs checking with representative cases. A high-volume SKU may deserve several lanes while a slower one needs less face. Reserve pallets above the picking levels are a separate load-capacity consideration.

As a division of Warehouse Equipment & Supplies Co., we bring storage-layout, quoting, and installation experience dating to 1997. Your consultation uses the measurements and photos you provide. You get the proposed layout and itemized scope before committing, with one contact to coordinate questions about delivery, installation, and later changes.

The project starts with the case list: dimensions, weight, whether the carton bottom is stiff or soft, and picks per SKU per day. Those numbers decide wheel bed style, lane width, and how much face each SKU is worth giving up.

From there we lay out the bay - how many flow levels, at what incline, and what sits above them. In most designs, the fastest movers get the golden zone at waist height, slower SKUs move to the upper or lower levels, and reserve pallets stack overhead in the same footprint.

The quote itemizes frames, beams, wheel bed or track, lane dividers, front stops, and shelf-level accessories, with the layout showing lane assignments by SKU. Installation sets the incline, tests case travel with your actual cartons, and adjusts before the line goes live.

The payoff is a pick line where cases present themselves, restocking stays out of the way, and lane widths can be reset whenever SKUs come and go.

We also compare normal replenishment intervals with peak pick demand so the face is not repeatedly emptied before restocking arrives. Representative cartons are checked for bottom stiffness, travel, and the behavior of the front stop. Where pallet reserve sits above case levels, the combined loading is reviewed as one rack configuration rather than two unrelated shelving projects.

Recent Installations

A sample of racking projects completed across the region.

Carton Flow Rack Questions We Hear Most

Where We Work

Located in Indianapolis, we serve the entire Greater Indianapolis region with industrial pallet racks and warehouse storage solutions.