Warehouse operations are under constant pressure to do more with less space, less labor, and less time. As order volumes rise, efficiency is no longer optional. There are several proven strategies to combat these challenges, but one of the best options warehousing and order fulfillment operations have is investing in space-efficient gravity flow rack systems.
By using gravity flow racks instead of static shelving, operations can ensure efficient product flow and faster, more accurate picking while optimizing storage density. Let’s take a deep dive into the key role gravity flow racks play in maximizing warehouse efficiency.
How Gravity Flow Racks Work
Gravity flow racks rely on a simple principle: carton or case loads are placed in the back of the rack and roll forward on tracks set at a slight incline. As items are picked, the next product moves forward automatically. This ensures:
- First-In, First-Out (FIFO) inventory stock rotation
- Constant product availability at the pick face
- Reduced time spent walking, searching, or replenishing SKUs
This type of dynamic storage is especially valuable in high-SKU operations where space is limited and pick rates must stay high.
Advantages of Implementing Gravity Flow Racks
The shift from static shelving to gravity flow rack systems brings measurable improvements across multiple areas of warehouse performance. Instead of storing products on fixed shelves that require constant restocking and excessive picker travel, flow racks create a dynamic storage environment where inventory moves forward automatically. This simple change can have a major impact on both productivity and cost savings.
Here are some of the key advantages warehouses experience when implementing gravity flow racks:
- Increased throughput: Because product is always positioned at the pick face, pickers never wait on replenishment or search for items. This consistent availability shortens cycle times and accelerates fulfillment.
- Reduced labor costs: By storing more SKUs in less space, gravity flow racks condense pick paths, reducing travel time and eliminating wasted motion. Gravity flow racks allow pickers to complete more picks per hour. This reduces the total labor required to meet demand.
- Optimized space utilization: Flow racks condense product into organized, higher-density storage lanes, making better use of both floor and vertical space. Facilities can store more SKUs without expanding their footprint.
- Better order accuracy: Defined carton flow lanes or flexible wheel beds provide clear organization, reducing the chance of grabbing the wrong SKU. This translates into fewer costly picking errors and returns.
- Scalability: Gravity flow racks can be configured for a wide range of applications, like case picking or each picking, so they can adapt as business needs evolve.
Together, these advantages make gravity flow racks a powerful tool for increasing efficiency, lowering costs, and building a warehouse operation that can scale with demand.
UNEX Gravity Flow Racks
UNEX provides a full line of carton flow products that can be used to create gravity flow racks tailored to your operation. The choice depends on whether you already have pallet racking in place, SKU mix, velocity, and how much flexibility you need.
Roller Rack: Standalone Gravity Flow Racks
If your facility doesn’t have pallet racking or if vertical space is limited, Roller Rack is the ideal choice. This standalone carton flow solution comes pre-configured with SpanTrack carton flow tracks. That means you’re not just buying racking, you’re buying a fully engineered gravity flow rack designed to improve pick rates immediately. Roller Rack is a plug-and-play option that minimizes installation time while delivering long-term ROI.
SpanTrack Lane: Organized, Defined Carton Flow Lanes
For operations that already have pallet racking in place, SpanTrack Lane carton flow rollers convert static shelving into high-performance gravity flow racks. Each lane is built to deliver consistent, jam-free product flow, ensuring items move smoothly to the pick face. SpanTrack Lane provides the structure and organization needed for case picking environments where SKU separation is critical. It can also be paired with Roller Rack to create standalone carton flow systems when required.
SpanTrack Wheel Bed: Maximum Flexibility for Changing SKUs
When SKU sizes and quantities change frequently, SpanTrack Wheel Bed offers unmatched adaptability. Its full-width bed of staggered wheels allows you to slot SKUs anywhere without reconfiguring fixed lanes. This makes it ideal for eCommerce, 3PLs, and other environments where inventory is constantly shifting. Like SpanTrack Lane, Wheel Bed can be dropped into existing pallet racks or installed within UNEX Roller Rack structures to create a standalone gravity flow rack system.
Why Choose UNEX for Gravity Flow Racks?
Every warehouse is different, and there’s no one-size-fits-all solution. UNEX designs carton flow and gravity flow racks that scale with your needs, reduce wasted motion, and deliver measurable gains in efficiency. Whether you’re outfitting a small pick module or a large distribution center, UNEX gravity flow racks help you:
- Maximize pick speed and accuracy
- Optimize floor and vertical space
- Lower operating costs through labor savings
- Adapt quickly to changing business demands
Take the Next Step Toward Efficiency
Gravity flow racks are more than just storage. They’re a strategy for creating faster, leaner, and more profitable warehouse operations. With Roller Rack, SpanTrack Lane, and SpanTrack Wheel Bed, UNEX delivers engineered solutions that transform static storage into high-performance, dynamic systems.
If you’re ready to reduce labor costs, increase throughput, and make the most of your space, it’s time to explore how UNEX gravity flow racks can work for your operation. Contact us today to get started!