Can Grandville teams pick individual items from these lanes?

Yes, open-case picking is possible with suitable cartons. The opening method must leave the container stable and provide access without disturbing adjacent lanes.

Should every product receive the same lane depth?

No, lane depth should reflect demand and replenishment practice. Giving every SKU identical space can leave slow sellers occupying room needed by frequent selections.

Will totes move on the same rollers as cartons?

Sometimes, but each tote base needs verification. Molded feet, ribs, or recessed bottoms can require a different roller arrangement from a flat-bottomed carton.

How does the arrangement support faster picking?

It presents stock at a consistent front location. The overall result also depends on slotting, clear identification, order routing, and timely replenishment.

Grandville, Michigan

Carton Flow Rack in Grandville, MI

Carton flow rack in Grandville gives small-order fulfillment a defined selection face, with cases moving down inclined roller lanes as stock is removed. Rather than reaching progressively farther into a shelf, operators work from the front while incoming cartons join the queue from a separate loading side behind the rack.

A useful arrangement begins with the order mix and the containers carrying it. Carton flow racking can serve full-case selection or open-case picking, provided the packaging travels predictably. We consider lane assignments, divider positions, refill quantities, and access together so a case flow rack fits the surrounding packing and replenishment work.

(616) 344-5683

How Carton Flow Rack Organizes the Order Path

Gravity supplies the movement, but lane geometry controls the result. Cases or compatible totes rest on inclined rollers and move toward a retaining stop. A trial using representative containers helps establish suitable support, side clearance, and presentation before the system is loaded for normal work.

Map the Selection Sequence

Arrange neighboring products around common order combinations so pickers can follow a readable route through the module.

Measure Container Variation

Include the widest expected carton and any protruding seams when deciding lane widths and the position of dividers.

Plan the Refill Side

Leave room behind the lanes for incoming cases, handling carts, and the motions needed to load each level.

Watch the Last Case

Test a nearly empty lane as well as a full one; movement should remain suitable as queued stock decreases.

Why Carton Flow Rack Suits Frequent Selections

Order picking speed often suffers when operators must search behind other products or pull cases forward by hand. A dedicated front position makes the next selection easier to locate. Clear labels and sensible SKU grouping matter just as much as the rollers beneath the stock.

FIFO comes from loading new receipts at the back and selecting earlier receipts at the front without bypassing them. Keeping those activities on opposite sides can reduce interference in a pick module. Slow-moving products may still belong on shelving if they do not justify a permanently assigned lane.

Product queues visible from the selection aisle

Adjustable divisions for changing carton sizes

Replenishment planned separately from packing

Carton flow rack with gravity wheel beds and case lanes

Carton flow shelving in use on a warehouse pick line

Keep Packing Within the Workflow

A selection face should not become a temporary holding shelf for completed orders. Show where cartons are packed and where empty packaging goes so those activities have space outside the active lanes.

E-commerce order fulfillment

Consumer product distribution

Fitting Carton Flow Rack Into Fulfillment Space

Retrofitting an existing pallet rack bay starts with checking its opening, supports, beam elevations, and stated loading limits. Inserts must suit that structure and leave usable access at the pick face. Any overhead reserve positions should be included in the review rather than treated as unrelated storage.

For e-commerce fulfillment along Chicago Drive, small boxed items might need more selection faces than replenishment depth. A flex building near Prairie Street could require a compact module beside packing tables. In either setting, the rack layout should preserve a clear handoff between picking, packing, and movement toward dispatch.

As a division of Warehouse Equipment & Supplies Co., Grand Rapids Pallet Rack has supplied and installed storage systems since 1997. Installation is performed by experienced crews whose work is scheduled and managed to suit the agreed operating sequence. Before handover, lane spacing, component placement, and package travel are checked against the planned arrangement.

For a Grandville installation, discuss work sequencing before approving delivery dates. Identify staging space, active shipping periods, and areas that must remain accessible. Clarify who verifies each completed section before the next begins. Ask for a handover checklist covering lane labels and roller settings. Clear coordination helps limit disruption while maintaining a safe, orderly work area.

Grandville storage planning Explore carton flow rack configurations Pallet flow options for Grandville Pushback rack choices in Grandville

Open-case lines with frequent repeat picks

Stable cartons needing dedicated positions

Modules beside order consolidation benches

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Recent Installations

Racking projects completed for warehouses across West Michigan.

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Review a Case-Picking Proposal

Bring your SKU list, package samples, and a sketch of the packing area. Discuss selection and refill priorities with our team at (616) 344-5683. (616) 344-5683.