Pallet Flow Rack Best Practices for Extra-Wide Inventory Loads | Mallard Manufacturing

Long inventory has a way of spreading out… on the floor, across aisles, and into wasted travel time. Pallet flow rack brings it back under control with high-density storage that keeps SKUs organized for accurate inventory management and helps protect products from damage compared to bulk floor stacks. For extra-wide loads (80"–94"), the best approach is to engineer lanes to the load profile so loading stays productive and extraction stays smooth and safe. In a recent Mallard test, we proved a simple, repeatable design: build the lane with three tracks of split-roller pallet flow, assist extraction with forklift separators, and manage flow velocity with FIBA speed controllers. The result is a pallet flow rack lane designed to accommodate extra-wide loads while supporting safe, efficient handling. Learn more about pallet flow rack: https://mallardmfg.com/full-split-rol... Contact the gravity flow rack experts at Mallard: https://mallardmfg.com/contact-us/ Go to the complete blog: https://mallardmfg.com/pallet-flow-ra... Read the blog excerpt below: Why Pallet Flow Rack Works for Long, Wide Inventory Long inventory has a way of eating up floor space, particularly if floor stacking is your alternative go-to: harder counts, harder (more risky) access, and a higher risk of product damage. A properly engineered pallet flow rack system helps you: Organize by SKU for easier tracking and accurate fulfillment Protect inventory with dedicated lane storage Maximize cube space while maintaining access and FIFO flow Improve handling consistency for long, bulky loads Mallard’s split-roller pallet flow solutions are ideal for customizing to handle difficult-to-manage, long, bulky loads, built around the product dimensions and flow requirements. The Test Setup: Lane Design for 80"–94" Wide Pallets Lane specs -- Lane length: 156" Roller tracks: 3-rail split-roller pallet flow Rollers: 1.9" diameter rollers on 2" centers Lane pitch: 7/16" pitch per foot Speed control: FIBA speed controllers installed every 48" Extraction control: Dual forklift pallet separators at the extraction end (pick face) Design intent: Three roller tracks create a stable lane for extra-wide pallets, while speed controllers help keep pallets centered and moving at a safe, controlled speed. Forklift separators at the end of the lane isolate the front pallet, making extraction easier by eliminating added pressure from the rear pallets. Pallet / load specs (tested) Load weights: 1,350 – 2,400 lbs Pallet construction: wood with 3-4 bottom boards each Evaluation: pallets had bottom-board damage (broken/missing boards), which is exactly the type of condition that can undermine safe, consistent pallet flow performance. Best Practices We Validated for Wide Pallet Flow 1) Engineer the lane to the load profile For wide pallets, the win isn’t a clever workaround—it’s a lane that’s built for the load specs. Using three tracks of split-roller pallet flow gives the lane the structure it needs to support extra-wide pallets and keep performance consistent. 2) Control flow velocity with speed controllers at consistent intervals Wide pallets can carry momentum differently—especially at heavier weights. In this design, FIBA speed controllers placed at 48" intervals helped manage velocity so pallets arrive more predictably at the pick face. 3) Stage extraction with forklift separators at the pick face Forklift separators help the operator by creating a more controlled pick-face experience. As pallets are removed, separators automatically set and reset, staging the next pallet to replenish the pick face in a controlled way. The Critical Variable: Pallet Quality (and Why Broken Boards Matter) In this test, one issue stood out fast: Broken and missing bottom boards can cause pallets to skip over the speed controllers and pallet separators—risking safe, efficient performance. Loading best practices (make this a standard habit) 1. Only load pallets in good condition into pallet flow lanes 2. Train your team to do a quick pallet check before loading (a fast review prevents slow problems) 3. Use donor pallets beneath compromised pallets to shore up damaged bottoms when needed If a pallet hangs up and the pallet is in good condition, often the simplest fix is to add another pallet to the lane to gently bump and prompt flow Forklift Extraction: What to Do (and What Not to Do) 1. Lift the pallet only a few inches above the lane to clear the end stops. 2. Back out carefully to fully extract the pallet. 3. Let the separator stage the next pallet as designed. 4. Avoid lifting too high You don’t want the pallet lifted excessively because it can activate the rear pallet release sooner than you want. Best practice is to lift just above the end stops and back out—this gives the operator time to fully extract the pallet before the rear pallets flow forward.