What should air freight forwarding teams check before ordering pallet flow rack?

Confirm whether FIFO is required by individual pallet, how many lots need separate lanes and the weight range entering each lane. Photograph pallet bottoms and identify damaged or inconsistent pallets. The layout then reserves access at both ends, and the selected conveyor components are checked with representative loads. Include peak inventory and the work that must stay active during installation, not only average loads. Keep lot-controlled freight advancing toward outbound picks despite uneven inbound truck appointments.

How deep should a pallet flow lane be?

Depth depends on pallet loads, turnover, and the lane design. Depth should match how much of one SKU moves through in a cycle - a lane that never fills is wasting a pick face. We size depth from your actual movement data, not a rule of thumb.

What keeps pallets from moving too fast down the lane?

Lane pitch is calculated for the load, and brake rollers or separators control travel from there. Pallets index forward at a controlled speed, protecting both product and frames.

Pallet Flow Rack warehouse storage system

Romulus, Michigan

Pallet Flow Rack in Romulus, MI

Romulus logistics operations work around airport-linked freight and truck appointments, so storage shortfalls quickly become dock problems. Near Detroit Metro Airport and the I-94 and I-275 junction, inbound loads may arrive in waves rather than an even stream. Reserve storage should absorb those receipts without blocking the cross-dock and outbound movements that keep the operation running. Keep lot-controlled freight advancing toward outbound picks despite uneven inbound truck appointments. A pallet flow rack system gives repeat inventory a defined route from receiving to retrieval. Pallets enter at one end and advance on gravity rollers toward the other, maintaining first-in, first-out order within the lane. The layout needs space at both ends, suitable pallets and controlled travel; it is not simply a deeper selective row.

For Romulus, the first step is a free warehouse design consultation that turns the storage problem into a layout and an itemized quote, not a guess about how many positions will fit. Send the load dimensions, weights and floor plan, and we will discuss the access and storage tradeoffs before specifying the system.

(313) 637-6214

Why Romulus Warehouses Work With Us

Detroit Metro Airport and the Vining Road and Wick Road distribution areas make Romulus a freight-oriented market. The rack plan needs to distinguish stock that will stay from freight that is only passing through. I-94 and I-275 provide access, while dock staging, replenishment windows and trailer turnover determine where dense storage can sit without interfering with daily handling. Keep lot-controlled freight advancing toward outbound picks despite uneven inbound truck appointments.

For pallet flow, we look at lot turnover, pallet condition and load variation together. Roller selection, lane pitch, braking and pallet separation follow the material actually moving. The receiving and retrieval aisles must remain usable at busy periods. We compare the position count against the number of distinct pick faces the operation needs. Detroit Pallet Rack, a division of Warehouse Equipment & Supplies Co., connects those decisions with the project quote. You receive a drawing to review, the proposed components and capacities, and an installation sequence tied to the work areas you can release. We discuss the tradeoffs with your operations team before ordering material rather than treating a higher position count as the only measure of a successful project.

Free warehouse consultation

CAD layout with position counts

Pallet rack delivery and installation

Pallet flow rack lanes with gravity rollers installed

Flow racking system loaded with pallets at the pick face

Operations We Rack Around Here

Local industrial corridors include the DTW air cargo area, Ecorse Road industrial, the I-275 and Wayne Road corridor, the Detroit Metro Airport freight corridor.

Air freight forwarding

Third-party logistics

Cold chain handling

Cross-dock operations

How Pallet Flow Rack Works

Load one side, pick the other, and let gravity enforce first in, first out.

Load end

Pallets enter at the high end of the lane. Each new pallet stages behind the one before it, so put-away is a single move made from the load-side aisle.

Gravity conveyor

Full-width rollers or skate-wheel tracks, set on a pitch calculated for the pallet weight, carry loads forward under control rather than free rolling.

Braking and separation

Brake rollers and pallet separators regulate travel and stop pallets from bunching, protecting both the product and the structure underneath it.

Pick end

Pickers work a face of first-in pallets. Pull one and the next indexes forward automatically, so the pick aisle stays organized without anyone re-facing stock.

What a Pallet Flow Rack Project Includes

Your Romulus pallet flow rack project begins with the current load list, a floor plan and a discussion of daily handling. For pallet flow, we look at lot turnover, pallet condition and load variation together. Roller selection, lane pitch, braking and pallet separation follow the material actually moving. The receiving and retrieval aisles must remain usable at busy periods. We compare the position count against the number of distinct pick faces the operation needs.

Flow racking is engineered per lane, not pulled off a shelf. Pallet weight, deck condition, bottom-board orientation, and desired lane depth all drive the roller or wheel selection and the pitch calculation, so the first step is pinning down exactly what's moving through the lane.

From there we set lane count and depth against your throughput. Fewer, deeper lanes maximize storage; more, shallower lanes give the pick face more SKU variety. Both versions get modeled with position counts so the tradeoff is visible before you buy, rather than after the order.

The itemized quote covers frames, beams, rail and roller assemblies, brakes, entry and exit guides, and guarding. At installation the crew sets pitch, tests loaded travel in every lane, and tunes brakes before the system goes live.

Afterward you have documented capacities, a lane map your team can hand to new hires, and a local contact for brake rollers and wheels as the system racks up cycles.

Delivery and installation are agreed against the approved drawing and the areas your team can release. We review access for unloading, the sequence of rows and the material that needs to arrive first. Confirm the load assumptions before handover and retain the layout and capacity records for future additions. If the product mix changes, review the affected levels or lanes before putting different loads into service.

For the the DTW air cargo area area, receiving access and active work zones are confirmed alongside the drawing. The final scope separates material, delivery coordination and installation so your team can compare proposals on the same basis. Keep the approved layout and capacity information for later changes rather than assuming a future load will fit the original design.

Date-coded food, beverage, and pharmaceutical inventory

High-volume SKUs with steady, predictable turns

Cold storage where every cubic foot carries a cost

Staging finished goods coming off a production line

Operations that need FIFO documented, not just assumed

Call (313) 637-6214

Recent Installations

Racking projects completed for warehouses across Southeast Michigan.

Pallet rack installation by Detroit Pallet Rack

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Get a Pallet Flow Rack Quote for Your Romulus Warehouse

Send the basics and we will follow up with a layout and pricing. Prefer to talk it through? Call (313) 637-6214.

Detroit Pallet Rack

19120 Grand River Ave.

Suite C

Detroit, MI 48223

(313) 637-6214

Monday - Saturday: 8:00 AM - 6:00 PM

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