Maximize Pick Module Efficiency with Dynamic Gravity Flow Rack
Pick modules are multi-level, high-efficiency storage and picking zones engineered for throughput inventory. Customized to your inventory specifications and operational needs, these systems integrate gravity flow racking and often conveyors to streamline product movement—from order picking to shipping. The result? Maximized productivity, accelerated pick rates, and optimized labor resources.
Gravity Flow Rack Solutions
- Carton flow rack - single item, case, & tote storage
- Pallet flow rack -
- Case pick from pallet for high-volume SKUs
- Reserve stock to replenish carton flow rack
- Push-back rack - reserve pallet storage
- Gravity conveyor - push-assisted roller and skate wheel options
By consolidating high-throughput case and each pick inventory in a small warehouse footprint, you increase efficiency and reduce travel times.
Advantages of a Well-Designed Pick Module
- Seamless Stock Replenishment: Automatic refill of the pick face from rear stock, ensuring uninterrupted operations
- Space Optimization: Consolidated SKU storage increases capacity up to 50% vs. static systems
- Enhanced Efficiency: Boosts pick rates while cutting labor costs by up to 75%
- Error Reduction: Orderly SKU lanes improve pick accuracy and streamline fulfillment
- Reduced Worker Travel: Consolidated, ergonomic footprint reduces worker fatigue and injury risk
Contact the Mallard team for a free consultation and a quote!
Carton Flow Applications for Pick Modules
Carton flow racking is a cornerstone of effective pick module design. This dynamic storage system features inclined shelves with rollers or wheeled tracks that propel cartons, totes, or boxes from the loading side to the picking side in organized SKU lanes. The dense design results in a steady stream of inventory at the pick face, boosting efficiency, accessibility, and accuracy in order-picking operations.
Watch how easy it is to add full-length dividers to your carton flow rack to ensure SKUs remain separate and promote faster, more accurate loading and picking.
How Can Carton Flow Enhance Pick Module Performance?
- Boost Productivity: Cartons automatically positioned at the aisle face
- Maximize Space: Up to 50% more storage vs. static rack or shelving
- Increase SKU Locations: Full shelf coverage maximizes pick faces
- Reduce Labor Costs: Save up to 75% in labor by minimizing travel and search time
- Enhance Ergonomics and Safety: Shelf positioning minimizes bending & reaching
At Mallard Manufacturing, we provide durable, low-profile carton flow products and optional accessories to meet your unique inventory and operational needs. Designed for long-lasting performance, our solutions handle a variety of inventory sizes and shapes, even in the most demanding warehouse settings.
Contact us today for a consultation and see how our tailored systems can boost your productivity and efficiency.
Pallet Flow Racking for Pick Modules
Pallet flow rack is the ultimate solution for high-volume case picking. In a pick module, pallet flow streamlines operations with individual SKU lanes that are multiple pallets deep. These lanes ensure a continuous supply of inventory at the pick face, making a perfect fit for high-throughput applications like beverage and grocery distribution. The pitched lane design automatically replenishes stock, keeping the pick aisle ready and efficient.
Additionally, using pallet flow as a push-back design supports efficient reserve stock access in the upper levels of the pick module for quick restocking below. This clever design minimizes forklift travel and boosts throughput—all while reducing labor and equipment costs.
How Does Pallet Flow Benefit Pick Modules?
- Greater Storage Capacity: Nearly doubles capacity compared to selective racking
- Increase throughput: Streamlines picking in a compact footprint
- Lower equipment costs: Requires fewer forklifts for operation
- Reduce labor costs: Minimizes forklift travel and pallet handling
- Enhanced inventory control: Ideal for dated and/or perishable goods
Our gravity flow rack experts will custom-design your pick module components to ensure maximized productivity. We recommend pallet separators for some case-picking applications, and you can even consider adding a lift table to minimize worker strain. Let’s discuss your options to find the most effective solutions for your team.
Safe and Efficient Empty Pallet Solution
Mallard’s empty pallet return (EPR) lanes ensure a safe, uncluttered workspace while protecting pallets from damage during removal. Customized to fit your pick aisle configuration, EPR lanes improve workplace safety and streamline operations.
Empty Pallet Return Lane Options:
- Single Pallet Return Lanes: For individual pallet removal
- Stacked Pallet Return Lanes: Allow for multiple pallets to be queued and safely removed
Contact the Mallard team today to discuss your needs and customize a system that maximizes productivity, safety, and cost savings!
Gravity Conveyor
Choose push-assisted push-assisted roller or skate wheel gravity conveyor as part of your customized pick module.
Maard products feature permanently lubricated ball bearings to maximize useful lifespan and minimize jams. Our heavy-gauge galvanized steel rollers support a variety of load requirements, including uneven or awkward containers.
How Gravity Conveyor Enhances Pick Modules
- Cost-Effective and Reliable: Easily transport materials from point A to point B with an affordable and efficient solution.
- Versatile Applications: Ideal for order fulfillment, kitting, and assembly
- Enhanced Safety and Durability: Features a unique roll-over frame design that protects workers from sharp edges and shields rollers from impact and debris.
