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8 Types Of Flow Rack System And Which Is Best Suited For Your Business

Flow rack system have optimized warehouse flow for decades as a space-saving, practical, and cost-effective solution—vertical flow and gravity transfer palletized products on constructed racks in an endless loop throughout the storage facility. 

As a result, shelves, forklifts, or even human interaction do not disrupt the flow of products. 

Since the introduction of the flow rack system, many businesses have benefited. Yet, developments in flow rack technology have occurred over time, and there are now several different types of flow rack systems to choose from. Hence, discussed below.

What Is A Flow Rack System?

Flow rack systems is a system that organizes pallets of products. Flow racks are arranged in rows, stacked 4 to 6 high on beams supporting the weight of all the pallets. Forklifts or machines pull out one pallet at a time while the other pallets are pushed back by an electric motorized belt to make space for the product being moved. 

  • Flow racks are designed for heavy-duty use and allow up to 1,200 pounds per square foot while having large spans between posts.
  • These are usually used for warehouse storage, with an average cycle time of two minutes. 
  • You can also use these in pairs or halves to create different configurations. These are designed to optimize warehouse space by using every square inch available. These are great for high-density storage because they have adjustable shelving.
  • These are also beneficial for companies with a high labor intensity because the system can move items without workers. It comes with different steel beams that allow flexibility in your order size for needs between 4 or 24 feet span widths. Flow racks are available in both powered and manual operation to meet customer requirements.
  • Flow rack systems are an excellent solution if you’re looking for forklift accessible storage that’s high-density, cost-effective, flexible, space-saving, and durable. 

It is are among the most popular warehouse storage methods because they provide advantages, including:

  •  Improved workflow
  • Fewer errors by moving employees away from product handling areas
  •  Increased productivity through ergonomic design
  •  Reduced costs due to less pilferage caused by human intervention

Flow rack systems are an excellent choice for new or expanding warehouses where space is premium, but you still need to store large quantities of palletized material.

Benefits of Using A Flow Rack System:flow rack system

Flow rack systems are an excellent choice for new or expanding warehouses where space is premium, but you still need to store large quantities of palletized material. A Flow Rack System has many benefits, which include:

 Less Handling Of Products

Flow racks reduce the risk of product damage by reducing manual handling activities and eliminating the associated costs. 

It can be integrated into your warehouse management software system, allowing automatic ordering and reduced labor requirements. 

It enables employees to spend less time fetching and more time on other essential tasks such as quality control.

 Improved Efficiencies By Moving Forklifts Away From The Product

Flow racks allow forklift drivers to push pallets from the side without physical contact with the product, preventing damage and increasing productivity. It also provides a safe area for human interaction by keeping forklifts away from people. It can improve efficiency by 30% over other storage methods because they combine reach trucks’ ergonomics with drive-in and drive-out configurations.

 Increased Productivity 

Flow rack systems allow employees to spend less time fetching and more time on other essential tasks such as quality control. It provides a safe area for human interaction by keeping forklifts away from people.

Why Install A Flow Rack System?

Flow racks are cost-effective. Its storage saves you money on labor and reduces insurance costs by reducing the risk of worker injuries related to high traffic or heavy lifting. Flow racks can be seen over forklift drivers’ heads, which eliminates the need for light fixtures in some cases. 

It allows you to move pallets with little effort, which lowers insurance premiums since there is less exposure to injury from forklift accidents. It eases material handling processes and increases warehouse efficiency by allowing your employees to spend more time on productive activities rather than walking around looking for products.

Additionally, Flow racks are available in many types suited for specific purposes, including flow racks used for holding products during production, flow racks for picking and shipping applications, flow rack systems used in the retail industry, and much more. 

Flow racks are essential in optimizing warehouse space while keeping it safe and organized. For decades, flow rack systems have served businesses well by being a space-saving solution that remains practical even today. You can apply flow racks to about any industry! 

Flow racks can help save a lot of time and money – It is an effective solution for any business. Flow Rack Systems have been around for decades and have served businesses well by being a space-saving solution that remains practical even today. 

Flow Racks are essential innovations in logistics today; A flow rack system offers many benefits that you cannot find anywhere else. 

Flow racks allow products to be passed from one worker to another without breaking the physical flow line. Flow rack systems have optimized warehouse flow for decades as a space-saving, practical and cost-effective solution.

What Are The Different Types Of Flow Rack Systems And Which Is The Best For Your Company?

Flow Rack Systems have been around for decades and have continued to evolve due to innovations by Flow Rack Companies. It is used in all industries because it can save space, provide easy access to products, improve worker efficiency, and create a safer work environment. 

Flow rack systems represent an investment that will pay itself off. Flow racks allow employees to spend more time on productive activities rather than walking around looking for products. 

Depending on your industry, there are many different types of Flow Rack Systems, including flow racks made out of steel or aluminum pallet racking.

Flow racks are usually used for warehouse storage, with an average cycle time of two minutes. There are many different flow rack systems on the market, so it’s essential to research before selecting one for your business.

1- Pharmaceutical 

When handled, drugs need special care because they are sensitive to temperature changes and other environmental factors. Flow Rack Systems with unique pharmaceutical Flow Rack Shelving ensure that the products are stored at constant, uniform temperatures. 

Flow rack systems for pharmaceutical storage have unique features that optimize efficiency, including low-profile capabilities and being forklift accessible. Pharmaceutical Flow Racks also protect products from the weather and spills, making Flow Rack Systems an excellent choice for storing top-shelf items.

2- Food 

Food Flow Racks make it easy to move food from processing areas to storage or loading and unloading areas without any spillage or damage thanks to things like fixed or adjustable flow racks for food. 

Also, open/close hatchway flow rack systems and glides on the bottom of Flow Rack Frames., making sure you’re using a Flow Rack System that is safe and efficient.

Flow Rack Systems for Food Storage: An Overview

Flow rack systems for food storage continue to evolve with a wide range of features, including:

  •  Flow Racks designed for forklift access
  •  Flow Racks that can handle pallets made from wood, plastic, or metal
  •  Flow Rack Systems designed for consistent temperatures.

Also, to improve warehouse layouts with Flow Racks, Flow Rack Companies work with their customers to ensure they get the most out of their Flow Rack Systems by providing personalized support throughout the design process.

3- Retail 

Retail Flow Racks provide an effective way of placing products on sale while keeping them organized and accessible.

There are several types of retail flow racks, including:

  • Flow Rack Systems with Flow Rack Shelves
  •  Two Way Flow Racks 
  •  Pole Flow Racks

Flow racks for retail keep products visible to customers, which creates the impression that there is more product on the shelf than exists. Retailers also use Flow Racks as a simple way of relocating products according to demand or seasonality, such as moving sweaters into an area where temperature control can help maintain appropriate conditions.

4- Apparel 

Apparel Flow Racks allow apparel companies to select and sort products like shoes and shirts while keeping them organized and accessible. There are many types of flow rack systems designed for organizing apparel, including: 

  • Open/close hatchway racks
  • Low profile flow racks
  • Flow Racks with Shelves
  • Made from steel or aluminum 
  • Designed to handle a wide variety of apparel.

Flow Rack Systems for the Apparel Industry has many features that optimize efficiency, including adjustable Flow Rack Shelving, open/close hatchway racks, and low-profile capabilities.

5- OEM 

Flow Rack Systems, designed for Original Equipment Manufacturers, combine elements from several types of Flow Racks mentioned above into a customized solution that facilitates production while saving space at the same time.

Also, to be efficient, Flow Rack Systems for OEMs protect products from damage during the manufacturing process, such as scratches and chips, making flow Picking a good in situations where product quality is essential. 

Flow Racks for OEMs are modular, making scaling production capacity easy by adding Flow Rack Shelves, Flow Racks, and Flow Rack Units as demand increases. Flow Rack Systems for OEMs also optimize warehouse space by featuring Flow Racks that are forklift accessible and ergonomic Flow Rack Frame Design. 

Flow racks create a safe working environment, and Flow Rack Shelves store the particular product. Flow Rack Frames are made with Flow Racks that can handle products of different sizes and Flow Rack Shelving that is adjustable. Flow Racks also feature Flow Rack Guards to prevent accidents.

6- Flow Rack System for Warehouses

Flow Rack Systems are made to handle large quantities of merchandise through efficient Flow Racks designed to improve warehouse layout. Flow Racks are also used in warehouses as Flow Pick Modules whereby pre-assigned Flow Racks are set aside for Flow Picking purposes., allowing pickers to access what they need to ship orders. This reduces travel time, saves time, and improves safety by decreasing fatigue.

7- Performance 

Performance Flow Racks provide the ultimate solution for optimizing storage space while maintaining low-temperature conditions. These systems are perfect for storing products like meats, fish, poultry, cheese, and dairy items because they ensure consistent temperatures throughout the flow rack system., which is not always possible with Flow Racks made from metal.

Flow Rack Systems for Meats, Fish, Poultry, Cheese, and Dairy are also made of plastic which prevents the transfer of flavors between products that may not be compatible., minimizing waste. 

Flow Rack Systems are customizable to suit flow picking needs making it possible to increase or decrease performance without extra investment by upgrading Flow Rack Shelving or Flow Rack Units as the need arises.

Flow racks provide businesses with a host of benefits, including:

  •  Reducing energy costs
  •  Optimizing warehouse space by working smarter instead of harder
  • Minimizing waste 
  • Creating a safer work environment.

8- Flow Rack System And Flow Pick Modules

Flow Racks have many benefits, including: 

  •  Improving production capacity 
  •  Reducing energy costs
  • Saving storage space 
  • Creating a safer work environment. 

Flow Racks also serve as Flow Pick Modules by creating Flow Rack Shelves designated for flow Picking to cut travel time and save time., money and improve safety. You can use flow pick modules in warehouses, distribution centers, retail stores, and anywhere else where goods need to be organized.


Flow Rack Systems is a critical component in any warehouse storage environment. It is designed to help companies optimize space while maximizing the efficiency of inventory procured. By using this system, companies can expect faster picking times, less travel time for employees, an improved working environment, and a host of other benefits.

Yankee Supply is an industry leader in warehouse and material handling supply. We have over 40 years of experience. Learn more about us here.

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