First-in, first-out (FIFO) inventory management is foundational for warehouses of all kinds. This simple method ensures the first stock that enters your warehouse is also the first to leave, preventing obsolescence and helping control costs.
While not the only type of inventory management system, it’s by far the most popular — especially when perishable goods are involved. As a result, many warehouse operators rely on storage solutions and layouts that support FIFO.
No warehouse storage solution is better for FIFO than carton flow rack systems, which are designed to push the oldest inventory to the front of the pick face using gravity alone. Here, we’ll explore how carton flow racks are made for FIFO storage, along with best practices for deploying this dynamic storage system in your warehouse.
Understanding FIFO (First-In, First-Out)
The FIFO storage method is simple: Stock new items behind older ones to ensure the older items leave the warehouse first. As orders are picked, workers grab the older items from the front of the pick face.
Implementing the FIFO method comes with several benefits:
- Waste reduction: FIFO inventory management is the most straightforward way to ensure older stock is used first, preventing products from expiring or going obsolete while hiding at the back of the shelf. This, in turn, optimizes inventory turnover rates by moving products efficiently through the warehouse.
- Enhanced product quality and customer satisfaction: FIFO methods prevent customers from receiving expired or obsolete goods, leading to a better experience with your brand.
- Regulatory compliance: Warehouses must follow numerous regulations about perishable goods, and FIFO simplifies this process to help your business avoid liability.
- Increased profit margins: Due to inflation, newer inventory is usually more expensive than older inventory. By selling older stock first, managers can ensure prices accurately reflect the cost of goods sold.
In short, FIFO is a key ingredient in warehouse space optimization.
Implementing FIFO With Carton Flow Rack Systems
Carton flow racks are a dynamic storage solution uniquely designed to fit the needs of FIFO inventory management. Unlike static or flat shelving, carton flow racks rely on inclined tracks with rollers or wheels to move products naturally toward the pick face. Items are stocked at the back and picked at the front, while gravity does the work of moving items from one end to the other.
Besides facilitating FIFO storage methods, carton flow systems enhance several aspects of warehouse inventory management and order fulfillment. When deployed properly, carton flow rack systems streamline stocking and picking processes. Having the oldest product readily available at the pick face reduces the time workers must spend searching for them. Likewise, carton flow racks allow for better use of floor space, condensing inventory into a smaller footprint for easier access.
However, these benefits aren’t automatic. Warehouse managers must consider several key factors to get the most from carton flow storage:
- Inventory type: It’s not necessary or beneficial to convert an entire warehouse to gravity flow shelving. Carton flow is most suitable for fast-moving products with high turnover.
- Weight and size of items: Wheel beds and rollers are designed for different product sizes and weights, and it’s critical to ensure inventory compatibility with rack specifications.
- Space and layout requirements: Successful implementation requires a review of the existing warehouse layout to determine the best possible location and use of carton flow systems.
- Integration with existing systems: Carton flow racks should integrate seamlessly into the larger flow of your warehouse, fitting with other dynamic and static inventory solutions.
Get The Definitive Guide to Carton Flow Storage and The Ultimate Order Picking Checklist. Download the guide today!
Optimizing Operations With FIFO and Carton Flow Racks
Before implementing carton flow rack systems for first-in, first-out inventory management, warehouse operators should carefully map out the new storage layout and optimized flow paths for stocking and picking. Installation may require a few hours, depending on the project scope.
Ultimately, your FIFO system is only as good as your staff training and ongoing maintenance plans. Employees must be thoroughly trained to use the FIFO system efficiently and effectively, and racks must be maintained to ensure rollers flow smoothly and lanes are properly set for seasonal inventory changes.
Of course, carton flow racks and other dynamic storage solutions are only one aspect of an effective FIFO system. Operators should consider other elements, including clear signage and barcode scanning, to establish consistent methods for tracking and managing inventory movement. Labels are particularly important for FIFO inventory management and should include SKUs and use-by, expiration, or received-on dates. Regular audits and stock checks can verify that what’s on the floor matches what’s in the system.
Warehouse optimization is never a finished project, either. Like any other aspect of warehouse operations, a new FIFO setup can be continually improved through ongoing feedback. Data collection is also invaluable for supporting informed decision-making about inventory choices and layout improvements.
UNEX Carton Flow Solutions
Selecting your carton flow solution is, of course, a crucial decision in the process of establishing or upgrading a FIFO inventory system. UNEX offers two industry-leading carton flow options: SpanTrack Lane and SpanTrack Wheel Bed.
Both solutions feature a simple drop-in design, making them easy to install in existing pallet racks without additional structural support. These sturdy carton flow tracks fit a wide variety of product weights and sizes, maximizing flexibility for seasonal inventory changes. They can be tailored to your warehouse’s unique needs with knuckled end treatments and to-the-inch sizing. Either style of carton flow will help you maximize storage density, enhance productivity, and improve picking accuracy in your warehouse.
Aside from their shared benefits, each SpanTrack carton flow solution is designed to fit specific operational needs, which we’ll explain below.
SpanTrack Lane: Carton Flow Rollers
SpanTrack Lane is the original carton flow rack, offering over 300% more product contact than plastic wheel beds for a smoother inventory flow. This evenly distributed pressure makes SpanTrack rollers ideal for operations with uniform inventory sizes or packages with irregularly shaped or uneven bottoms.This increased surface area results in:
- Better flow with fewer hang-ups
- Increased throughput
- Optimal support for a wide range of carton sizes and weights
Key Features:
- Integrated label holder system for clear inventory management
- Customizable to-the-inch increments for precise fitting
- Versatile end treatments for easy attachment to any pallet rack setup
- Available in light, standard, and heavy-duty capacities
- Freezer/cooler rated for use in cold storage environments
SpanTrack Wheel Bed: Carton Flow Beds
SpanTrack Wheel Bed is made for facilities with frequent inventory changes or variations in size. Beds are flexible to accommodate varying SKU sizes, and built-in shark fin infeed guides are fully adjustable to allow for re-slotting. This design features:
- Universal wheel beds for easy left-to-right adjustments
- Patented hex hub wheel design for optimal flow
- Built-in shark fin infeed guides to ease replenishment and allow for re-slotting
The low-friction hex hub wheel design of SpanTrack Wheel Bed promotes an optimal product flow for greater picking and stocking efficiency. Overall, this carton flow system is ideal for dynamic warehouses with constantly changing inventory needs.
Key Features:
- Available in various widths to fit different bay sizes
- Customizable to-the-inch increments for precise fitting
- Light, standard, and heavy duty capacity choices
- Freezer/cooler rated for use in below-zero environments
- Versatile end treatments for easy attachment to any pallet rack setup
Take the Next Step Toward Efficient Inventory Management
FIFO storage methods are a foundational aspect of warehouse optimization, essential for reducing waste, improving product quality, and managing the cost of goods. Carton flow racks present one of the easiest ways to support FIFO initiatives for fast-moving inventory. These dynamic storage solutions are designed to facilitate proper inventory sequencing, support efficient picking, and enhance space utilization.
Still, effective carton flow implementation requires careful planning to ensure you select the right product for your situation. Everything from warehouse layout to SKU variety must be considered, along with your ideal inventory flow.
UNEX can help you compare options and choose the best carton flow solutions for your needs. Contact us today to explore storage solutions tailored to fit your warehouse.
