Carton Flow Racking

Why Upgrade to Dynamic Carton Flow Storage?

• Maximize Storage Density: Optimize the full height and depth of existing pallet racks to condense your overall footprint and store up to 300% more product contact area than traditional plastic wheel rails.
• Ergonomic “Golden Zone” Picking: Cartons automatically flow forward to the front of the rack, keeping items comfortably within the picker’s ergonomic reach while eliminating unnecessary bending, reaching, and workplace strain.
• Streamlined FIFO Rotation: Gravity-driven tracks ensure the oldest inventory is always picked first, simplifying date-sensitive stock management and preventing perishable goods or time-sensitive SKUs from spoiling.
• Zero-Interference Operations: Separating the loading aisle (rear) from the picking aisle (front) allows replenishment and order picking to occur simultaneously without traffic bottlenecks or equipment interference.
• Drop-In Versatility: Patented track designs drop seamlessly into existing structural or roll-formed pallet rack systems with minimal effort, allowing you to reconfigure or relocate lanes as your inventory profile evolves.

Industry-Leading Carton Flow Solutions

As an authorized provider of UNEX systems, Shelf Master offers robust, American-made gravity flow solutions engineered to handle anything from small split cases to heavy beverage kegs. Every solution is backed by an industry-leading 7-year warranty.

SpanTrack Lane

Dedicated, heavy-duty roller lanes designed for fixed or predictable SKU locations. Engineered to drop directly into existing pallet rack structures, these durable roller tracks provide maximum surface contact to distribute weight evenly, ensuring smooth product flow without hang-ups on the track. <p>

SpanTrack Wheel Bed

Made-to-order, full-width wheel beds that offer ultimate left-to-right flexibility for warehouses with frequently changing SKU dimensions. The continuous wheel surface allows you to easily re-slot boxes, cartons, and totes of varying widths without needing to move physical track dividers.<p>

SpanTrack Keg Flow

A specialized gravity flow solution custom-engineered for beverage distribution and hospitality storage. Keg Flow maximizes floor space and streamlines stock rotation for heavy beer kegs, keeping high-demand beverages organized, ergonomic, and easily accessible. <p>

Shelf Track

A durable, drop-in replacement system designed to upgrade unreliable, lightweight plastic wheel rails. Shelf Track provides up to 300% more product contact than standard plastic wheels, preventing carton imprinting and eliminating track deformation over time.

Custom Applications & Industry Uses

Whether you are managing a 3PL distribution center in Southern California, a retail fulfillment hub, or a refrigerated food and beverage facility, our engineering team tailors wheel centers, track styles, and end stops to your specific operational demands:

• E-Commerce & 3PL Order Fulfillment: Accelerate split-case and each-picking operations with high-visibility layouts that minimize picker search time and order errors.
• Food & Beverage Storage: Ensure strict FIFO compliance for date-coded inventory while keeping workers out of cold storage environments faster through rapid pick lines.
• Automotive & Manufacturing Lineside Storage: Supply assembly lines with a continuous, gravity-fed presentation of parts, hardware, and components in heavy-duty industrial totes.

Partner with Shelf Master for Turnkey Warehouse Efficiency

For over 50 years, Shelf Master has designed, engineered, and installed turnkey material-handling systems throughout Anaheim, California, and nationwide. Our specialists evaluate your carton weights, box conditions, environmental factors (such as humidity or freezer storage), and order volume to configure the exact roller centers and track pitches required for foolproof product flow.

Contact our Anaheim design team today at (800) 847-4353 or request a quote online to engineer a custom carton flow system that maximizes your warehouse space and picking productivity.

Frequently Asked Questions About Carton Flow Racking

What is the difference between dedicated roller lanes and full-width wheel beds?

The choice between rollers and wheels depends on your inventory consistency:

• Dedicated Roller Lanes (SpanTrack Lane): Ideal for fixed or predictable SKU locations where box dimensions remain consistent. The solid roller design provides maximum surface contact to eliminate hang-ups and ensure consistent gravity flow.
• Full-Width Wheel Beds (SpanTrack Wheel Bed): Recommended if your SKU dimensions change frequently or vary widely. Because the wheels span the entire bed left-to-right, you can easily re-slot different-sized cartons, boxes, and totes without moving physical track dividers.

How much more efficient is carton flow racking compared to static shelving or pallet picking?

Upgrading to dynamic carton flow can increase order picking throughput by up to 150% compared to picking directly from pallets or static shelving. By consolidating inventory into an ergonomic pick face and separating the stocking aisle from the picking aisle, warehouses typically reduce walking time and cut associated labor costs by up to 80%.

Can I integrate carton flow tracks into my existing pallet racking?

Yes. Modern carton flow systems like SpanTrack and Shelf Track feature a modular, drop-in design. They install directly into existing structural or roll-formed pallet rack beams without specialized tools or structural modifications. If your layout changes, the tracks can be easily lifted and relocated to different bays or facilities.

What are “roller centers” or “wheel centers,” and why do they matter?

Roller or wheel centers refer to the spacing between individual rollers or wheels along the track. Choosing the correct center spacing is critical for smooth material flow and prevents boxes from stalling or dipping between wheels. When designing your system, our Shelf Master engineering team evaluates your specific variables—such as minimum and maximum box lengths, carton weights, bottom tote materials, and environmental humidity—to specify the exact center spacing needed for foolproof gravity flow.

Why replace standard plastic wheel rails with metal track systems?

Traditional lightweight plastic wheel rails deform over time, cause carton imprinting, and often lead to product hang-ups. Upgrading to heavy-duty, engineered solutions like Shelf Track provides up to 300% more product contact area, ensuring even weight distribution, superior durability, and reliable First-In, First-Out (FIFO) stock rotation.

Are these carton flow systems covered by a warranty?

Yes. Through our partnership with UNEX, the carton flow storage systems supplied by Shelf Master are backed by an industry-leading 7-year warranty, guaranteeing long-term performance in demanding warehouse environments.

What information do I need ready to get a quote or design consultation?

To design an optimized carton flow layout for your facility, our Anaheim specialists typically look at:

• Existing Rack Specs: Beam length, depth, and upright type (structural vs. roll-formed).
• Inventory Profile: Minimum and maximum dimensions (length, width, height) and weights of the cartons, split cases, or totes being stored.
• Environment: Dry warehouse, refrigerated cooler, or freezer storage.
• Flow Goals: Desired number of SKU pick faces and replenishment frequency.

Ready to configure your custom carton flow system? Contact our Southern California material handling team at (800) 847-4353 or request a quote online to get started.