Too often, the workflow in a third-party logistics (3PL) warehouse looks like a relay race. Orders surge and omnichannel fulfillment accelerates, leaving workers running to keep up.
Meanwhile, 3PL providers must sort out how to handle an overtaxed workforce. More than three-fourths (76%) of supply chain and logistics leaders reported significant staffing shortages in 2024. As SKU counts grow and demand rises, the need for speed, accuracy, and flexibility in warehousing and order fulfillment only grows.
Fortunately, carton flow systems offer a sensible option for 3PL teams facing these challenges. These storage solutions help 3PLs optimize space, reduce travel time, and accelerate order fulfillment. Here’s how carton flow can improve efficiency across your 3PL picking operations.
Speed and accuracy of fulfillment are consistently among consumers’ top priorities when ordering online. Even as pressures for same-day or next-day deliveries have eased, basic expectations have stayed constant: Shoppers want to know when they will get their items, and they want those items to arrive on time.
Further complicating matters, 3PLs usually support multiple clients with fluctuating order volumes, varied SKU mixes, and constantly evolving storage needs. Without an efficient picking system in place, bottlenecks arise to slow fulfillment and strain labor.
Amid such complex logistics, inefficiency can snowball quickly:
With profits and scalability on the line, 3PLs must make every second count. That starts with creating smarter picking workflows.
Carton flow systems are dynamic storage solutions that use gravity to automatically feed products to the pick face for efficient visibility and order picking. Stockers load inventory from the rear onto slightly inclined shelves, and the cartons move forward on wheels or rollers so the next item is always in position for picking, creating seamless first-in, first-out (FIFO) inventory rotation.
By simplifying replenishment and accelerating the picking process, carton flow storage creates a significant operational advantage for 3PL warehouses that manage thousands of fast-moving SKUs. Carton flow systems improve several critical aspects of 3PL efficiency:
In short, carton flow gives 3PLs an immediate operational lift. But its real strength lies in how well it scales and adapts.
Adaptability isn’t an option in the world of 3PL fulfillment. Bringing on a single new client can add hundreds of SKUs, each with unique sizes, turnover rates, and replenishment requirements. Seasonal fluctuations, promotional surges, and shifting order profiles can quickly overwhelm static storage systems, leading to slowed operations, errors, and rising labor costs.
Carton flow systems are built to absorb these shifts without disrupting productivity. Carton flow rollers or wheel beds allow for easy SKU re-slotting, making inventory changes simple, so you can respond quickly to shifting client needs without costly downtime.
Carton flow organizes SKUs at the pick face and shortens pick paths by condensing the overall footprint of your order picking zones. Better organization and shorter pick paths result in reduced travel time and keep orders moving efficiently. Meanwhile, gravity-fed replenishment eliminates wasted motion and keeps products always within reach. Carton flow also reclaims space in previously underutilized areas of racks and shelving. This provides greater storage density and throughput for your operation.
Order volumes can swing dramatically in 3PL warehouse, especially in industries like grocery, retail, or consumer packaged goods. The flexibility that carton flow affords these operations is invaluable, translating to faster turnaround, lower labor hours per order, and higher client satisfaction. Plus, the rugged construction of these storage systems stands up to constant use and varied packaging types, ensuring long-term reliability in demanding environments.
UNEX offers industry-leading carton flow systems for 3PL providers looking to accelerate their picking speed. SpanTrack Lane and SpanTrack Wheel Bed are both engineered for smooth product flow, exceptional durability, and easy installation, and they’re proven to increase throughput by 150% compared to static shelving.
Both storage options share key features that simplify setup and improve ergonomics. Their drop-in design means they fit seamlessly into any standard pallet rack with no need for shelves or intermediate supports. Knuckled end treatments or pick trays can be added to further reduce strain by tilting products toward the picker, and a variety of end treatments can help tailor the system to a range of workflows.
Built for high-volume operations with a steady lineup of predictable SKUs, SpanTrack Lane carton flow rollers deliver smooth, uninterrupted product movement that keeps pickers operating at peak efficiency. With 300% more surface contact than plastic wheel rails, they minimize carton hang-ups, improve stability, and accelerate case picking. Optional adjustable pick trays enhance ergonomics and accessibility, making SpanTrack Lane carton flow rollers perfect for split-case or each picking applications as well.
For 3PL warehouses, these advantages translate directly into measurable gains. Stable, jam-free flow reduces costly interruptions and ensures pickers can process more orders per shift, driving higher throughput without additional labor. The system’s durability and ability to handle heavy full-case picks mean fewer maintenance issues and a longer lifecycle, critical for facilities managing multiple clients with demanding SLAs.
At the same time, the flexibility to adapt to split-case or each-pick applications makes SpanTrack Lane versatile enough to support a wide variety of fulfillment models. By reclaiming unused space within racks and maximizing pick-face density, 3PLs can store more SKUs in less space, streamline replenishment, and scale their operations without costly facility expansions.
SpanTrack Wheel Bed is engineered for maximum flexibility, making it the ideal carton flow solution for 3PL warehouses managing constantly changing client inventories. The universal wheel bed design provides up to 90% bay coverage, accommodating cartons of varying sizes and shapes without the need for fixed lanes. This maximizes pick facings per bay and eliminates wasted space, while optional infeed guides and guide rails ensure fast, friction-free replenishment that keeps pickers productive, even during peak demand.
For 3PLs, that flexibility is a game-changer. Tool-free re-slotting allows bays to be reconfigured in minutes, supporting rapid client onboarding, seasonal transitions, or sudden shifts in order profiles, all without disrupting operations. SpanTrack Wheel Bed reduces labor waste and accelerates picking speed so warehouses can process more orders with the same headcount.
And by optimizing every inch of rack space, 3PLs gain the ability to expand SKU capacity without expanding their footprint. The result is a system that not only keeps pace with unpredictable client demands but also drives higher throughput, better space utilization, and long-term scalability.
The pace of 3PL fulfillment is only accelerating, and warehouses that rely on static storage quickly hit bottlenecks that slow throughput, drive up labor costs, and limit scalability. Carton flow systems are no longer optional; they are essential tools for 3PLs that need to move faster, stay organized, and adapt to shifting client demands.
With UNEX carton flow, you do not have to choose between stability and flexibility. SpanTrack Lane delivers smooth, stable product movement for predictable, high-volume SKUs, while SpanTrack Wheel Bed provides the re-slotting agility to keep up with constantly changing client inventories. Used individually or together, they give 3PLs the ability to maximize pick face density, reclaim wasted rack space, and push more orders out the door without expanding their footprint.
Explore UNEX carton flow solutions like SpanTrack Wheel Bed and Lane today to see how your operation can improve throughput, cut wasted motion, and scale with confidence.