CARTON FLOW

Hand Loaded Gravity-Fed System

Carton Flow is a dynamic storage system designed to improve picking efficiency and inventory rotation. Using gravity-fed roller tracks, cartons or cases are loaded from the rear of the rack and automatically move forward to the picking face as items are removed. This creates a First-In, First-Out (FIFO) flow that keeps products organized, accessible, and consistently replenished. Ideal for warehouses, distribution centres, and order-picking environments, carton flow systems increase pick speed, reduce travel time, and make better use of valuable storage space.

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Across North America

Continuous Flow. Designed To Improve Order Picking Speed.

Quick And More Efficient
50% Faster Picking

Carton Flow keeps products automatically positioned at the front of the rack, so pickers always have immediate access to inventory. As cartons are removed, the next case rolls forward into place, eliminating the need for constant restocking at the picking face. This significantly reduces travel time and keeps pickers focused on picking instead of searching for products. In high-volume environments, this streamlined workflow can increase picking productivity by up to 50%, helping warehouses process orders faster while reducing labour effort.

High SKU Density
in a Small Picking Area

Carton Flow allows a large number of SKUs to be presented within a highly organized and compact pick zone. Each product is stored in its own dedicated lane, ensuring clear product separation and easy identification during picking. Because cartons automatically advance to the front, pickers can access a wide variety of items within arm’s reach without needing to walk through multiple aisles. This efficient use of space allows warehouses to support large SKU counts while maintaining fast and accurate order fulfillment.

Modular Integration
With Existing Racking Systems

Carton flow modules can be installed within standard pallet racks or shelving systems ( such as Unirack, Unishelf, Super123, Super456 SuperBuild ), allowing warehouses to create multi-level pick modules or retrofit existing storage systems without rebuilding the entire layout.

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FAQ

A carton flow system is a gravity-fed storage solution designed for fast case and carton picking. Products are loaded from the rear of the rack and move forward on roller tracks as items are removed, ensuring cartons are always available at the picking face. This design improves picking efficiency and keeps inventory organized for high-volume order fulfillment.

Carton flow improves efficiency by automatically presenting cartons at the front of the rack, reducing the need for operators to walk, reach, or search for products. As cartons are picked, the next one moves forward into place, allowing pickers to maintain a continuous workflow and significantly increase picking speed.

In many warehouse environments, carton flow systems can improve picking productivity by up to 50%. By reducing travel time and keeping products consistently positioned at the pick face, operators can focus on picking orders instead of navigating storage aisles.

Carton flow systems are ideal for warehouses with large SKU counts and frequent order picking. They are commonly used in distribution centres, e-commerce fulfillment operations, retail replenishment, and manufacturing environments where products need to be picked quickly and efficiently.

Yes. Carton flow modules can be installed within standard pallet racking or shelving systems, making them easy to integrate into existing warehouse layouts. At ShelvingMate, carton flow can be installed within systems such as Unirack, Unishelf, Super123, Super456, and SuperBuild, allowing facilities to upgrade picking efficiency without rebuilding their entire storage setup.

Carton flow systems allow multiple SKUs to be stored in dedicated lanes within a compact pick zone. Because cartons automatically advance forward, operators can access a large variety of products within a small area, increasing SKU density while maintaining efficient picking access.

Carton flow is widely used in industries that require fast and accurate order fulfillment, including retail distribution, e-commerce, automotive parts, electronics, pharmaceuticals, and manufacturing assembly operations.

We don’t just sell the system—we install it too. Our in-house installation crew ensures everything is set up safely, correctly, and ready to use. You won’t need to coordinate with outside contractors.