Gravity Flow Racks

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Flow Racking
Span Track - Bed
Span Track - Lane
Gravity Conveyors
Pallet Track
Pick Shelves
Roller Racks

Gravity Flow Racks

Gravity Flow Racks and Carton Flow Systems for Faster, FIFO Order Picking

Gravity flow systems use gravity instead of power to move product where it is needed. Carton flow racks and tracks pitch cartons and totes toward the picker as items are removed, pallet track does the same for full pallets, and gravity conveyors carry packages down the line. Stock loaded from the back is picked from the front, which keeps inventory in first-in, first-out (FIFO) rotation.

The racks you can order online include Lyon gravity flow racks with galvanized wire decking and UNEX FlowCell racks with SpanTrack roller lanes, SpanTrack wheel beds, or tilted pick shelves. These units each have 4 adjustable levels, stand 72" or 84" tall, and come 24" to 48" deep and 48" to 96" wide. The rest of the collection, including Span Track beds, Span Track lanes, roller racks, pick shelves, pallet track, and gravity conveyors, is designed around your layout and storage needs and quoted by our team.

Every gravity flow project is different.

Flow racks are sized to your SKUs, pick rates, and space, so we recommend talking through your project with our team before you order. Request a quote or call 800-637-9508.

Comparing Gravity Flow Rack Types and Systems

Gravity flow comes in two forms here: complete racks you can order online, and carton flow, pallet flow, and conveyor systems that our team configures to your racking and products.

Type How It Works Best For How to Buy
Lyon Gravity Flow Racks Freestanding racks with pitched galvanized wire decking, rated 1,000 lbs per level (standard) or 3,000 lbs per level (heavy-duty) Medium- to heavy-duty carton and tote picking Order online
UNEX FlowCell Racks Complete freestanding flow racks with SpanTrack roller lanes, wheel beds, or tilted pick shelves Ready-made pick bays sold as starter and add-on units Order online
Span Track Bed Drop-in wheel bed track that turns existing pallet rack levels into carton flow Weaker boxes, stacked cartons, and cold storage Request a quote
Span Track Lane Drop-in, all-metal roller lanes for existing pallet racks Durable carton flow that reslots as SKUs change Request a quote
Roller Racks Span Track carton flow on a lightweight beam-and-post frame that stands alone or combines into bays Dense carton picking without building out full pallet rack Request a quote
Pick Shelves Angled steel shelves added to Span Track or mounted in racking on their own Partial-case picks and slow-moving items Request a quote
Pallet Track Roller or wheel tracks that let full pallets flow through pallet racks FIFO pallet storage with fewer forklift trips into the rack Request a quote
Gravity Conveyors Unpowered roller or wheel bed conveyor, with gate and curve options Moving cartons from the pick line to packing and shipping Request a quote

Quoted systems are sized to your rack, cartons or pallets, and pick strategy, and final capacities are confirmed during configuration. Request a quote or call 800-637-9508 to talk through your project.

Per-Level and Per-Unit Capacities Are Different

UNEX FlowCell racks are rated up to 1,000 lbs per level but 3,000 lbs per unit, so you cannot load all four levels to their maximum. Plan your heaviest SKUs around the total unit rating, not just the level rating.

Tilted pick shelf capacity also changes with size, from 400 lbs per shelf on 24"d x 48"w units up to 1,000 lbs on the largest sizes. Check the rating on each product page before you assign inventory.

How to Choose the Right Gravity Flow Rack

Start with how your inventory moves, then match the rack to its size, weight, and pick rate. Our team can work through each of these with you as part of a quote.

Check these before you order:

  • Pick rate: Fast movers suit flow lanes or wheel beds; slow movers suit tilted pick shelves.
  • Product mix: Note how often SKUs and carton sizes change, and whether boxes are weak or stacked, since both affect the track type.
  • Carton depth: Choose a rack depth that holds the number of cartons you want behind each pick face.
  • Weight: Check both the per-level and per-unit capacity against your heaviest loads.
  • Run length: Start with a starter unit, then add add-on units to extend a FlowCell run.
  • Loading access: Leave room behind the rack for restocking from the rear.

Where Gravity Flow Racks Are Commonly Used

Flow racks are a common choice wherever pickers fill many orders from a fixed set of SKUs.

Distribution Centers

High-volume carton and each picking with FIFO rotation.

Ecommerce Fulfillment

Pick faces for fast-moving SKUs near packing stations.

Manufacturing and Assembly Lines

Line-side parts replenished from the back without interrupting work.

Food and Beverage Distribution

Date-sensitive stock kept in first-in, first-out order.

Healthcare Facilities

Supplies rotated and restocked without disturbing the pick side.

Automotive Parts

Organized lanes for frequently picked parts and components.

Gravity Flow Rack FAQs

Answers to common questions about FIFO, starter and add-on units, loading, and assembly.

How do gravity flow racks keep FIFO inventory rotation?

Each level is pitched toward the pick side. New stock is loaded from the back and slides forward behind older stock, so pickers always take the oldest item first.

What is the difference between a starter and an add-on FlowCell?

A starter unit stands on its own and begins a run. Add-on units connect to an existing starter to extend the run, so a row of three FlowCells is one starter plus two add-ons. Match the depth and height of each add-on to the starter.

Do flow racks keep cartons from sliding off the front?

Yes. UNEX FlowCell racks with roller lanes and wheel beds have end stops at the pick face, and Lyon gravity flow racks use wire decking with waterfall edges to hold product in place.

Can the levels be adjusted?

Yes. All racks in this collection have 4 adjustable levels. Lyon racks adjust on 1-1/2" centers without tools.

When should I contact Shelving.com about a flow rack project?

Call if you are planning a full pick line, converting existing racking, or need a size not listed here. Our team offers free site visits and consultations and installs jobs nationwide.

Gravity Flow Rack Resources

Learn how flow storage fits your picking operation and see it in action.

Static Storage vs. Flow Storage

Compare the pros and cons of static shelving and flow racks for your inventory.

Read the Article →

Flow Racks, Inventory, & You

How flow racks support inventory rotation and picking efficiency.

Read the Article →

Gravity Flow Case Studies

See how distributors and manufacturers improved picking with gravity flow racks.

Read the Case Studies →
Warehouse storage optimization whitepaper

Take control of your warehouse space!

Download our warehouse storage optimization whitepaper to learn how to make the most out of your warehouse layout, without outrageous costs and additional real estate requirements.

Talk Through Your Gravity Flow Project With Our Team

Gravity flow racks are tailored to each operation. Share your SKUs, carton sizes, pick rates, and available space, and we will recommend a system and put together a layout and quote.

Request a Quote Or call 800-637-9508
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Gravity Flow Racks

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We don’t just sell stellar shelves. We design custom organized spaces that fit your needs, large or small.

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Let Us Install For You

We don’t just sell stellar shelves. We design custom organized spaces that fit your needs, large or small.

We Can Help You