How Pallet Flow Rack Design Keeps Custom Crates Moving | Mallard Manufacturing

Watch how rack design, forklift approach, and unloading process support safer, more controlled operation. Not every pallet flow rack design starts with a standard GMA pallet. In real warehouse operations, loads come in different shapes, weights, and bottom-runner configurations. That is why Mallard gravity flow solutions are customized around each customer’s inventory and load specifications, then tested to confirm the lane can perform under real-world conditions. For this application, our team evaluated a full roller pallet flow lane designed for custom wooden crates with three bottom runners. The team focused on three critical points in the pallet flow rack design: Flow: controlling the crates to help them stay centered and move consistently down the lane Separation: creating the right gap between the pick-face crate and rear loads Extraction: showing how forklift technique affects unloading, indexing, and separator protection Watch the full test video to see how the lane design, separator, speed control, and unloading process work together before the system reaches the floor. Learn more about roller pallet flow rack: https://mallardmfg.com/full-split-rol... Contact the Mallard gravity flow rack team: https://mallardmfg.com/contact-us/ Go to the complete blog: https://mallardmfg.com/how-pallet-flo... Read the blog excerpt below: The System Tested: Full Roller Pallet Flow with a Forklift Separator This application calls for a full-roller pallet flow lane transitioning to split-roller, with a forklift separator at the forward pallet location near the pick aisle. Skate wheel rails were installed along the sides of the lane to help keep the crates centered as they flowed. That centering detail mattered because of the crate construction, particularly the bottom, where it makes contact with the flow lane. The wooden containers provided by the customer have three bottom runners: one on each outside edge and one down the center. For this flow lane design to work, the center runner must make contact with the forklift separator for the mechanism to engage properly. Pallet Flow Lane Design: Full roller pallet flow lane - 53” out to out to evenly support the crates Split roller with Forklift Separator at discharge end to isolate the crate at the pick face Skate wheel rails along the sides of the lane to help guide and center the loads FIBA speed controllers and a 1/2-inch-per-foot lane pitch worked together to control the velocity of the advancing loads As you can quickly tell, this is a custom lane configuration. While a warehouse team may know the storage objective, the load itself often determines the best path forward for gravity-flow rack design. Testing is the best way to confirm all the details before the system is installed in the field. What the Flow System Test Confirmed The test produced positive results as the crates flowed down the lane. The speed controllers helped keep the wooden containers under control, and the Forklift Separator provided the separation needed between the discharge crate and the rear crates in the lane. During unloading, the rear crates indexed forward as the front crate was removed. For warehouse managers and engineers, the test highlights several practical takeaways: ✔ Lightweight loads can flow effectively when lane pitch, rollers, and speed control are properly matched. ✔ Non-standard bottom runners must be reviewed to confirm reliable separator function. ✔ Side guidance can be critical when the load has a narrow or centered contact point. ✔ Separator performance depends on the pallet style, load condition, and bottom-runner quality. ✔ Operator technique is essential to successful pallet flow performance. How the Forklift Separator Works The Forklift Separator (FL Separator) is installed in the front pallet position. As the crate flows over the separator, its center runner depresses the forward paddle, causing the rear paddle, or hold-back device, to rise and stop the rear loads from advancing. That action creates a gap between the front position and the rear crates. The front position is isolated and can be removed without any back pressure from the rear crates. As the front crate is lifted, the separator paddle underneath rises. When it is fully extended, the rear paddle drops, allowing the next crate to flow forward and refill the pick face. For this sequence to work reliably, the crate must stay aligned in the lane. In this test, skate wheel rails helped keep the crates centered, allowing the middle runners to trigger the separator consistently. Near the end of the test video, you will see how a crate with a missing center runner fails to engage the separator, signaling a caution about ensuring crates are intact before loading into the pallet flow lane. During the test, the team also demonstrated proper and improper forklift extraction for the forklift separator.