Wholesalers and business-to-business (B2B) operators typically move a lot of inventory at scale. Case picking — the process of selecting full cases or cartons to fulfill orders — is a go-to method for managing high-volume inventory. But while case picking is designed for efficiency, the reality is that disorganized layouts, poor SKU management, and outdated systems can quickly clog the flow of goods and drain profits.
The key to unlocking true efficiency lies in combining case picking with smarter storage solutions. Carton flow systems, in particular, can transform your case picking process, boosting speed, organization, and productivity. Let’s explore how integrating carton flow storage can supercharge your order fulfillment and keep your operation running smoothly.
Understanding Case Picking and Its Challenges
Case picking refers to a warehouse operation where full cases or cartons of products are selected from storage to fulfill customer orders. This method is particularly efficient for fulfilling large or wholesale orders that require full cartons rather than individual items or entire pallets.
Unlike each picking, which is prevalent in business-to-consumer (B2C) sectors like eCommerce and third-party logistics (3PLs), case picking is common in B2B industries where bulk orders are typical, such as beverage distribution and wholesale. In some cases, you’ll find case picking solutions in hybrid warehouses such as retail distribution centers and some 3PL facilities, which serve both B2B and B2C clientele. Wherever high-velocity SKUs require frequent replenishment — think grocery stores, liquor wholesalers, and logistics hubs — there is likely a case picking application.
However, many case picking operations are poorly executed and thus fail to provide the maximum value. Common challenges include:
- Space constraints and inefficient layouts: Case picking operations often face significant warehouse footprint expansion to handle a growing number of high-velocity SKUs. Poor space utilization can lead to increased picker travel distances and search times, slowing down operations and reducing overall efficiency.
- Poor ergonomics and worker turnover: Case picking frequently involves repetitive movements such as bending, reaching, and lifting heavy cartons. This can lead to worker fatigue, higher rates of injuries, and increased turnover.
- Lack of FIFO stock rotation: Without effective first-in-first-out (FIFO) processes, older stock can get buried, leading to inventory waste and reduced product quality.
- Disorganization by throughput: Failing to organize SKUs by velocity or throughput often results in delays or missed orders, as pickers spend excessive time searching for the correct items.
- SKU management challenges: Medium- to high-velocity SKUs can exacerbate operational inefficiencies if not properly stored in easily accessible shelving. This often results in double-handling or misplaced inventory during replenishment and picking.
The Role of Carton Flow in Optimizing Case Picking
Carton flow storage offers a straightforward and highly effective way to address these challenges by streamlining inventory storage and picking processes. A carton flow system uses angled, gravity-fed tracks — rather than static, flat shelves — for efficient product flow, enabling easy restocking and order fulfillment.
This system is ideal for boosting case picking efficiency. With carton flow, wholesalers and B2B operators get:
- Efficient carton handling: Carton flow systems are designed to manage the weight and dimensions of full cases. Their durability and full-width roller designs prevent product hang-ups and support smooth carton movement in an environment where entire cartons are frequently handled.
- Streamlined restocking: Carton flow systems streamline full-carton replenishment by allowing easy restocking from the back while maintaining clear access for pickers at the front, reducing interruptions and enhancing productivity.
- Optimization for high-density case storage: Case picking often requires maximizing the storage density of medium-to-high-velocity SKUs. Carton flow systems allow multiple cases to be stored compactly, saving space while keeping full cartons readily available for picking.
- Enhanced worker safety: Unlike each picking, case picking regularly involves handling heavier items. Carton flow tracks position cases at an ergonomic height, reducing picker strain and injury risks specific to lifting full cases.
Overall, carton flow storage is an ideal match for case picking. In wholesale or beverage distribution environments, where large orders of full cases are common, carton flow systems facilitate a structured picking process. This prevents misplaced cartons and ensures consistent flow tailored to case picking demands.
Learn how SpanTrack helped this wholesale distributor maximize space and expand operations. Download the Case Study.
Best Practices for Efficient Case Picking with Carton Flow
Carton flow systems can transform your case picking processes, but merely introducing gravity-flow shelving won’t yield the best results. Implementing the following best practices will ensure you get the most out of your carton flow setup.
1. Store Inventory According to Throughput
The most important step in boosting case picking efficiency starts with a mindset shift. To optimize order fulfillment, you must stop grouping inventory by similarity and start organizing it by throughput.
Fast movers belong with fast movers, Likewise, medium movers belong together. And both should have dedicated space on carton flow racks. Reserve slow-moving SKUs for angled pick shelves or or high-density storage like SpeedCell.
When your warehouse storage is optimized according to throughput, you’ll see all kinds of benefits, including increased capacity, reduced variable costs, and improved employee performance. You’ll also see a drop in turnover combined with an increase in attendance—employees who know what to expect daily in a well-organized operation that is not as physically demanding as others generally want to stick around.
2. Maximize Space Utilization
As a dynamic storage solution, carton flow systems are designed to maximize the use of space within the warehouse. Unlike static shelving, gravity flow storage lets you condense more inventory into a smaller footprint while making more products visible to pickers.
Carton flow shelves also allow you to utilize more vertical space. Their angled pick face brings more cases within reach, ensuring pickers can grab full cases quickly and easily. Don’t let that extra usable space go unused — squeezing more inventory into a smaller footprint reduces worker travel time and may even help you avoid premature warehouse expansion.
3. Maintain FIFO Inventory Control
Implementing carton flow storage gives your warehouse an immediate advantage when it comes to inventory freshness among fast movers. You just have to take advantage of it.
With carton flow, you can easily store inventory FIFO without any need for reshuffling cases or double-handling products. Stockers feed new inventory into the back of the shelf, slotting it directly behind old inventory. As workers pick cases from the front, the newer inventory automatically slides down toward the pick face for the next order.
Relying on gravity-fed systems radically reduces the time spent looking for older inventory and reduces waste. Products no longer get lost on the back of the shelf, only to go bad rather than shipping out at the right time. This is especially critical in case picking operations, where a single expired case may represent significant inventory value.
4. Reduce Picker Travel Time
We already mentioned the time you can save workers by slotting inventory by velocity. But what if you think bigger, organizing high-volume items strategically by zone to minimize worker movement when fulfilling orders?
Group your top full-case items together in high-volume zones and place them near the shipping area. This simple layout change can increase picking speed by limiting individual workers to a much smaller fulfillment space. You’ll save on labor, and your employees will save their energy.
5. Enhance Ergonomics
By angling cases toward the picker, gravity-fed shelves already have built-in ergonomic enhancements. You can take these a step further by adding knuckled end treatments to put products even closer to pickers.
By lowering the front of the rack and putting the next case right in front of workers, you can minimize the amount of reaching and bending they need to do. You can also strategically place heavier cases at waist or chest height to reduce the risk of back strain when lifting cases off the shelf.
Spotlight: UNEX Carton Flow Solutions for Case Picking
UNEX offers two dynamic storage solutions designed for carton flow: SpanTrack Lane and SpanTrack Wheel Bed. Both products feature durable, sturdy tracks with a drop-in design to easily convert static shelving to a gravity-fed system. Likewise, both can be customized with a variety of end treatments to fit the needs of your case picking setup.
SpanTrack enables easy FIFO rotation and facilitates more efficient SKU organization and case picking. There’s no need for double-handling inventory, as cases will easily slide to the pick face as orders are fulfilled. SpanTrack carton flow solutions also improve ergonomics and eliminate unnecessary picker strain, reducing turnover and workers' compensation claims.
Both options can also be tailored to fit various inventory weights and volumes. While medium-duty applications are most common in case picking operations, you can also custom-fit SpanTrack shelving to suit lightweight and low-volume cases or heavy-duty storage and product flow. For instance, even if you’re moving a high volume of heavy liquor cases, SpanTrack’s durability reduces wear and tear, minimizing maintenance costs over time.
Choosing SpanTrack Wheel Bed vs. SpanTrack Lane for Case Picking
Is one SpanTrack option better than the other? Ultimately, each can have a place in your case picking system.
SpanTrack Lane is ideal for slotting SKUs of predictable shapes and sizes, or for applications that require maximum support for heavy-duty or fragile products. Its full-width roller design provides 300% more product contact than alternatives, ensuring smooth handling of cases without hang-ups. It’s also particularly well suited for medium- to high-velocity SKUs in case picking.
SpanTrack Wheel Bed offers unparalleled flexibility for facilities handling a more diverse mix of carton sizes or frequently changing SKU configurations. Its adjustable pick lanes with shark fin infeed guides facilitate easy slotting, re-slotting, and inventory replenishment, making it perfect for operations managing varied carton dimensions. Additionally, the low-friction hex hub wheel design allows for fast and efficient case flow during stocking and fulfillment.
Transform Your Case Picking Efficiency with Carton Flow Solutions
No case picking setup is complete without a carton flow storage system. Pairing carton flow with case picking enables better organization, faster stocking and fulfillment, and more efficient movement for your fastest movers. Plus, it unlocks the full benefits of FIFO storage and enhances worker safety.
With two durable, customizable carton flow systems, UNEX has everything you need to implement an efficient case picking setup in your warehouse. Whether you require heavy-duty storage for your top-selling beverages or a mix of case sizes for a high-volume 3PL operation, SpanTrack Lane and SpanTrack Wheel Bed can set you up for case picking success. Contact us today to explore the benefits of pairing carton flow with your case picking operation.
