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Roller Racks — Carton Flow That Saves Space, Time & Money
Increase warehouse efficiency with Roller Rack carton flow. Roller Racks can mean up to 80% less travel time for pickers and 7x more SKU density per bay.
Whether used alone or combined into a bay, Roller Racks are configured to your products, pick strategy, and space—not sold off the shelf.
Roller Rack Features
Roller Racks use Span Track carton flow on a lightweight, fast-to-install frame—delivering dense, efficient picking without the steel and labor of full pallet rack.
- Installs fast with adjustable keystone beam clips
- Frame uses less steel than pallet rack
- Faster to install and knock down than pallet rack
- Modular design for bays or standalone units
- Ensures FIFO rotation
- Up to 7x more SKU density per bay than pallet rack
- 80% less travel time for pickers
- Restock without interrupting the pick line, backed by a 7-year warranty
Built on Span Track — Bed or Lane
Roller Racks are built with Span Track carton flow, available in two main varieties so you can match the rolling surface to your cartons.
- Span Track Bed: a full-width wheel surface with up to 300% more product contact—great for weaker boxes and stacking capacity
- Span Track Lane: an all-metal roller surface built for flexibility and effortless reslotting
Learn more about Span Track Bed and Span Track Lane.
Roller Rack Configurations
Roller Racks are available in two main configurations. Each can be ordered with Span Track Rollers or Wheel Beds.
- Roller Rack: four lanes of Span Track that stand alone or combine into continuous bays.
- Knuckled Roller Rack: four lanes of Span Track with internal knuckles that angle cartons for easy picking—perfect for partial-case picks.
Tech Specs
Roller Racks combine a lightweight beam-and-post frame with your choice of Span Track carton flow. Final capacities are confirmed during configuration.
- Beams: 1.5" x 3.5" beams, available in 4' and 8' widths and 5', 6', 8', and 10' depths.
- Posts: 1.75" square tube with 2"-on-center keystone punching.
- Carton flow: Span-Track Lane or Span-Track Bed, knuckle or straight.
Real-World Example
George J. Falter Co. in Baltimore, MD replaced an undersized, failing pick line in an existing mezzanine—where busted plastic wheel tracks let product fall through and slowed workers down—with a modern carton flow system, restoring fast, safe picking across a growing range of convenience-store SKUs.
Frequently Asked Questions About Roller Racks
Shelving.com helps warehouse and fulfillment teams compare Roller Racks with pallet rack, choose Span Track Bed or Lane, and gather the details needed before requesting a quote.
What is a Roller Rack?
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A Roller Rack is a carton flow rack built on Span Track and a lightweight beam-and-post frame. Cartons flow forward by gravity to the pick face, delivering up to 7x more SKU density per bay than pallet rack and up to 80% less travel time for pickers.
How are Roller Racks different from pallet rack?
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The Roller Rack frame uses less steel than pallet rack and is faster to install and knock down. It's purpose-built for dense, FIFO carton picking rather than full-pallet storage.
Can Roller Racks be combined into bays?
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Yes. The modular design lets Roller Racks stand alone or combine into continuous bays. Each unit uses four lanes of Span Track.
What's the difference between a Roller Rack and a Knuckled Roller Rack?
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A standard Roller Rack uses four straight lanes of Span Track. A Knuckled Roller Rack adds internal knuckles that angle cartons for easier picking—ideal for partial-case picks.
Do Roller Racks ensure FIFO rotation?
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Yes. Cartons load at the back and flow to the front, so the oldest stock is always picked first. You can also restock without interrupting the pick line.
How do I get a quote for Roller Racks?
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Share your carton sizes and weights, SKU count, pick strategy, and available space. We'll recommend the right configuration, Span Track Bed or Lane, and bay layout, then quote the system.
Carton Flow & Picking Resources
Roller Racks are built on Span Track and pair with the rest of our picking systems. Explore related solutions to design a complete pick line for your operation.
Span Track Bed
Wheel bed carton flow with up to 300% more product contact for weaker boxes and up to 90% space utilization—one of the rolling surfaces inside a Roller Rack.
View Span Track Bed →Span Track Lane
The original all-metal roller carton flow, built for flexibility and effortless reslotting as your SKUs change.
View Span Track Lane →Pick Shelves
Angled steel pick shelves that kill the rear dead zone—add them to your pick line for partial-case picks and slow movers.
View Pick Shelves →Start Your Roller Rack Plan
Tell us what you pick, and we’ll help configure the right carton flow rack.
We Can Help YouStart Your Roller Rack Plan
Tell us what you pick, and we’ll help configure the right carton flow rack.
We Can Help You