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SpanTrack Carton Flow Systems

Discover The Original Carton Flow Track!


Optimizing the footprint of a fulfillment operation - whether it’s multiple warehouses, a fulfillment center, a retail backroom, or customer pickup areas - requires careful planning. Inventory organization plays a pivotal role in determining how best to maximize space in any facility. The primary way inventory is stored and organized across industries is with industrial shelving systems. Static storage solutions like pallet racking with wire deck or flat steel and rivet shelving are common storage mediums found in facilities large and small. While this may be the default or basic starting approach to storage, there are more advantageous ways to maximize throughput across fulfillment operations.In this article, you will discover SpanTrack - what it is, who it’s for, and the advantages of implementing this dynamic system.

What is SpanTrack

SpanTrack is an innovative carton flow system that drops into existing structures to create a robust flow solution for any operation. SpanTrack uses full-width roller lanes or wheel bed tracks and the power of gravity to flow items from the back to the front of a pallet rack bay. These carton flow tracks create automatic FIFO stock rotation while maximizing space within your pallet racks.

SpanTrack carton flow tracks are extremely configurable with different flow options like aluminum or steel rollers, plastic wheel beds, or steel skatewheels. This carton flow system is offered in light, standard, and heavy-duty capacity options. End treatments are customizable, from pick tray add-ons to knuckled ends and more. Guard rails, slow-down strips, in-feed guides, swing stops, and more accessories can be added to optimize performance based on your needs.


Who Benefits from a SpanTrack Carton Flow System?

SpanTrack is ideal for case picking and each picking (also known as split-case picking) operations in warehousing, order fulfillment, and retail settings. It is also a great solution for industrial settings like manufacturing and assembly plants due to its durability. This dynamic shelving solution can be found in a variety of facilities that store many different types of products. Some examples include:

  • Apparel and Footwear
  • Automotive Retail
  • Beer, Wine, Liquor
  • Cannabis
  • Consumer Packaged Goods (CPGs)
  • Convenience Retail
  • Cosmetics
  • Electronics
  • Grocery/Cold Chain
  • Hardware
  • Pharmaceuticals
  • Toys and Hobbies

As eCommerce and omnichannel fulfillment operations expand and increase retail market share, order picking grows in use and scope. Any operation where order picking occurs can benefit from the use of SpanTrack somewhere in the facility - whether it’s one bay or one thousand, depending on the unique needs of the operation.


When it comes to throughput, SpanTrack is well-suited for storing medium to high-throughput SKUs or “fast-movers.” We can’t talk about SpanTrack without providing at least a crash course in throughput, so here it is…

What is Throughput, and Why Should I Care?

Throughput is the rate of production or the speed at which something is processed. Across the supply chain, throughput refers to the number of units processed per time interval and typically quantifies the outbound operations within a facility.

Slow-moving SKUs are a necessary evil. These SKUs are purchased infrequently, so they don‘t need a high-profile position in your facility. However, they still need to be stored in an easily accessible location. Storing these SKUs in a very dense dynamic industrial shelving system like UNEX SpeedCell is ideal.

Medium-moving SKUs typically make up the bulk of your operation while fast-moving SKUs usually represent the bulk of an operation’s revenue stream. The best way to store these SKUs is in a carton flow system like SpanTrack.

Medium and high-throughput SKUs earn your operation the most money, so focusing on the best way to maximize space in your facility for these SKUs is key. Storing items according to throughput will result in maximum ROI.

Learn to optimize warehouse space for increased speed and accuracy. Download the Guide to Understanding Throughput for Fulfillment!


The SpanTrack Advantage

Whether adding more SKU storage within your existing footprint or setting up an entirely new space, SpanTrack carton flow systems deliver unparalleled efficiencies for a wide range of businesses. Unlike static shelving, SpanTrack offers:

  • Versatility: SpanTrack can be added to any new or existing pallet rack. No shelves or intermediate support is required.
  • Superior Flexibility: SpanTrack provides the flexibility to store products with a wide variation in size and weight.
  • High Capacity and Durability: SpanTrack takes the abuse of active warehouses and assembly plants.
  • Unrivaled Flow: SpanTrack provides maximum carton support and up to 300% more product contact than plastic wheel rails, resulting in better flow, fewer hang-ups, and increased throughput.

Full Case Picking with SpanTrack

Low Profile SpanTrack carton flow rollers drop into existing pallet rack, creating FIFO storage lanes that are ideal for full case picking. Designed to ensure FIFO product rotation, SpanTrack carton flow rollers present cases or cartons to workers so they can easily pick orders without reaching and bending into racks. Storing products in carton flow systems condenses and organizes SKUs to reduce travel time and maximize space utilization.


Each Picking with SpanTrack

SpanTrack carton flow rollers optimize each picking with adjustable pick trays that present open cases to order pickers. In each picking applications, workers pick products from split cases without interference from the shelf level above. SpanTrack carton flow systems can maximize space within your facility and increase throughput up to 150% compared to picking eaches from cases stored on pallets at ground level


SpanTrack boosts the profitability of entire facilities by creating organized and space-efficient storage. Maximizing space, improving SKU organization, and product flow translates to increased pick speeds and reduced labor costs.

SpanTrack improves pick facings, making it vastly more ergonomic and efficient for your team members to pick SKUs for order fulfillment. This means you can quickly improve the profitability of your operations without moving to a new space or buying entirely new equipment.

Top Companies Choose SpanTrack

Fresh Direct

Manhattan-based online grocery service, Fresh Direct, provides New Yorkers with a way to get their groceries delivered directly to the customer’s front door. Fresh Direct employees pick 63,000+ orders per week, averaging 8.5 lines per order and 10 items per order.

To keep Fresh Direct’s grocery service moving without interruption, UNEX replaced old carton flow tracks at about 4,000 product locations with SpanTrack at Fresh Direct’s Borden Avenue warehouse. When Fresh Direct opened a new warehouse, UNEX equipped the entire 70,000-square-foot facility with SpanTrack.

Learn how UNEX carton flow helps Fresh Direct maximize space and increase pick rates. Download the Case Study. 


Types of SpanTrack Carton Flow Systems

SpanTrack is offered in a variety of track styles. These efficient, durable, and dependable tracks create the ultimate carton flow system for operations from the manufacturing floor to the retail store. Regardless of track style, SpanTrack carton flow systems offer many features that make it the leading solution in the industry. 

SpanTrack Key Features

  • Add to any new or existing pallet rack; no shelves or intermediate support required
  • Drop-in design for easy installation
  • Freezer/cooler rated to below zero
  • Light, standard, and heavy-duty options available
  • Knuckled end treatment for improved ergonomic each picks
  • Customizable end treatments that attach easily to any pallet rack setup
  • Interior notching to save vertical space
  • Available in to-the-inch increments
  • Integrated label holder system
  • Optimized for product stacking
  • 7-year warranty

UNEX-SpanTrack-Lane-Circle-2SpanTrack Lane

If the dimensions of your product mix stay static throughout the year, full-width roller lanes are a great fit for your carton flow system. SpanTrack Lane allows you to create dedicated lanes of carton flow that are optimized to keep your inventory efficiently flowing to the point of pick. Lanes can be designed in varying widths to match your product mix and increase your overall storage density. This carton flow system can help operations with a consistently sized product mix realize significant space and time savings.

SpanTrack Lane is capable of storing products with a wide variation in size and weight. This strong and sturdy solution is more than capable, even in the most active warehouses and assembly plants. Plus, SpanTrack Lane eliminates hang-ups with 300% more product contact compared to outdated and unreliable plastic wheel rails.

UNEX-SpanTrack-Wheel-Circle-1SpanTrack Wheel Bed

If you need to accommodate a wide variety of product sizes, wheel bed carton flow systems are an ideal fit. SpanTrack Wheel Bed floods an entire level or bay of a storage rack with independently rotating wheels. This allows you to slot varying sizes of products on the same level while maintaining maximum flow and storage capacity.shelf-track-wheel-bed-1

SpanTrack Wheel Bed offers the most flexibility in a carton flow system. SKUs can easily be re-slotted as needed and inventory can be re-configured for seasonal variation in your product mix. UNEX SpanTrack Wheel Bed "shark fin" infeed guides can be added to ease replenishment from the rear and SpanTrack Wheel Bed's hex hub wheel design allows for optimal flow.

UNEX-SpanTrack-Keg-Flow-Circle-1SpanTrack Keg Flow

SpanTrack Keg Flow gets kegs off the ground and gives beer distributors room to grow. This high-density keg storage solution replaces palletized storage, consolidates floor space, reduces bending for workers, and improves stock rotation. With a SpanTrack keg storage solution, beer distributors can offer more beer variations in a small space while improving worker efficiency and productivity.

SpanTrack Keg Flow increases storage density by as much as 200%! It reduces travel time and mispicks while also reducing wear on aluminum kegs. Keg Flow keeps kegs tight and upright to ensure maximum space utilization is achieved.

SpanTrack Keg Flow Key Features

  • Each lane handles both 1/6 and 1/4 slim kegs
  • For 1/4 and 1/2 barrels, consult with a product specialist for design
  • Same track drops into channel or step beams, interchangeable
  • 1-3/8″ diameter heavy-duty steel rollers
  • Double deep model FIFO stock rotation
  • 11-3/4″ wide tracks allow storage of 8 kegs across in a 96-inch wide bay
  • High roller stop for easy ergonomic keg “roll-out” and less wear on aluminum kegs
  • 6″ common heavy-duty guard rails to keep kegs upright
  • Available in single and double-deep lanes
  • Impact and slow down skid plates on double deep Keg Flow
SpanTrack Lane Carton Flow Rollers

Efficient, durable, and dependable, SpanTrack Lane carton flow rollers drop into existing structures to create the ultimate carton flow rack system for manufacturing facilities and order picking operations.

SpanTrack Carton Flow Beds

SpanTrack wheel beds are flexible carton flow beds that drop into existing structures to create the ultimate flow rack system for order picking operations, manufacturing facilities, and more.

SpanTrack Keg Flow

SpanTrack Keg Flow gets kegs off the ground and gives beer distributors room to grow. This high-density keg storage solution replaces palletized storage, consolidates floor space, reduces bending for workers, and improves stock rotation.


Let UNEX Help You Maximize Space with SpanTrack

Maximize space utilization, improve organization, and increase pick speeds in your operation when you upgrade your static shelving to a SpanTrack carton flow system. UNEX offers total solutions for your storage needs, including free engineering support for your SpanTrack project. Contact us today to explore the possibilities for your operation!

Explore the basics of carton flow storage systems in our FREE Guide.