When should I choose carton flow rack?

Carton flow suits case picking, with replenishment behind the lanes and a consistent picking face. Selective teardrop is the default for mixed SKUs; pushback stores two to six deep LIFO by SKU; pallet flow supports FIFO or dated stock; drive-in suits bulk quantities of few SKUs; cantilever supports long loads; carton flow serves case picking. We compare access, rotation and occupied positions before recommending a system.

How much weight can carton flow rack hold?

There is no single capacity that applies to every configuration. Beam capacity is per pair, per level; frame capacity depends on height and beam spacing. We size beams and frames from your heaviest pallet and put the capacities on load plaques. Carton lanes and any pallet reserve above them are checked together using case and pallet weights.

Can you supply and install carton flow rack for my Zionsville warehouse?

Yes. We handle design, supply and installation with experienced installation crews we schedule and manage. The system is anchored to the floor, aligned to the approved layout and handed over with its load capacities documented.

How much does carton flow rack in Zionsville cost?

Price depends on pallet positions, rack height, beam capacity, decking, freight and installation. Send your pallet size, heaviest load per level, clear height and building size for a free CAD layout and itemized quote.

Can I add carton flow rack to my existing pallet rack?

Usually, if the connections and rated configuration match. "Teardrop" is not universal across manufacturers: send photos of the upright face, beam connector and any label so we can match compatible new components. A conversion also needs the frame depth, component capacities and operating clearances checked for the selected system.

Carton Flow Rack system inside a Indiana warehouse

Zionsville, Indiana

Carton Flow Rack in Zionsville, IN

A Zionsville fulfillment team can waste pick time walking between scattered static shelves even though the building already has ample pallet reserve behind them. Fulfillment storage needs short case-pick routes as well as enough reserve pallet capacity. That makes consolidate active cartons near packing and replenish from a defined rear route a practical design question for this building, not a reason to order the largest system in a catalog. Carton Flow Rack in Zionsville, IN starts with understanding that constraint. Carton flow shelving advances cases toward a consistent hand-picking face on inclined wheel beds or roller tracks. Rear replenishment access can keep restocking separate from picking. Carton dimensions, bottom stiffness, pick frequency, and the time between replenishment runs decide lane width and reserve depth.

Send your floor plan and load information or call (317) 659-6552; we will work through the fit before quoting.

(317) 659-6552

Why Zionsville Warehouses Work With Us

Zionsville business space along Michigan Road and toward neighboring Whitestown serves operations with different scales of inventory. A fulfillment team may value a short path from case picking to packing more than the largest possible reserve count. We show those active working routes on the drawing before reserve storage fills the remaining space. Connections toward I-65 help with delivery coordination, but they do not determine the right picking arrangement inside the building. Your order mix, replenishment interval, and available staff are the inputs that decide where a denser or gravity-fed system earns its place.

For this carton flow rack project, the specific task is to consolidate active cartons near packing and replenish from a defined rear route. 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.

Free warehouse consultation

CAD layout with position counts

Delivery and professional installation

Carton flow rack with gravity wheel beds and case lanes

Carton flow shelving in use on a warehouse pick line

Operations We Rack Around Here

Nearby areas we work in regularly include I-65 corridor, Zionsville industrial park, Michigan Road corridor, Whitestown Parkway edge.

E-commerce fulfillment

Consumer products

Distribution

Specialty retail supply

How Carton Flow Rack Works

Cases advance to the picker instead of the picker hunting for cases.

Inclined wheel beds

A full-width wheel bed or roller track sits on a slight incline inside a standard bay, so cases move forward under their own weight without power.

Pick from a fixed position

The picker always reaches for the same forward spot in the lane. Travel time drops, and so does the time spent searching for the next case.

Restock from behind

Replenishment loads the high end of the lane from a separate aisle, so restocking can stay separate from the pick line, and rotation stays first in, first out automatically.

One lane per SKU

Lane dividers set the width for each case size, giving every SKU its own face - a width that can be resized as your product mix shifts.

What a Carton Flow Rack Project Includes

The Zionsville project starts with the operating information you provide: carton sizes, bottom stiffness, case weights, picks per SKU, replenishment intervals, and working reach heights. We also review the floor plan, fixed obstructions, usable height, and the working routes around Michigan Road and the southern Boone County business corridors. Your specialty retail supply, consumer-product shipping, and order fulfillment schedule helps identify which zones need immediate access and which can be set aside for installation.

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.

Case and each picking operations

Order fulfillment lines carrying many active SKUs

Grocery, beverage, and consumer goods distribution

Kitting and light assembly feed lines

Bays that need reserve pallets stacked above the pick face

Call (317) 659-6552

Recent Installations

Racking projects completed for warehouses across Central Indiana.

View More Projects

Get a Carton Flow Rack Quote for Your Zionsville Warehouse

Send the basics and we will follow up with a layout and pricing. Prefer to talk it through? Call (317) 659-6552.

Indianapolis Pallet Rack

9105 E 56th St.

Ste J #2291

Indianapolis, IN 46216

(317) 659-6552

Monday - Friday: 8:00 AM - 6:00 PM

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