Can carton flow be built into a multi-level pick module near BWI?

Yes. Each level has a walkway with flow lanes facing it while restockers work the far side and a belt runs past the pickers. The full module is drawn as one plan.

How do polybagged e-commerce items work on carton flow?

Put them in totes. Totes roll consistently on wheel rails, while loose polybags tend to stall.

What is the golden zone in a pick module?

Roughly waist to shoulder height. The busiest SKUs go there, often with extra lanes, while slower SKUs take upper or lower shelves.

Do you install carton flow and pick modules in Hanover?

Yes. We design and supply the system, and installation is done by experienced crews we schedule and manage. Timing is confirmed on the quote.

Carton Flow Rack system inside a Maryland warehouse

Hanover, Maryland

Carton Flow Rack in Hanover, Maryland

Carton flow rack in Hanover is a core part of the e-commerce and 3PL pick modules going into tall buildings along the BWI and MD-100 corridor.

Cases and totes ride pitched rollers to the pick face. Restocking happens from a separate aisle behind, so pickers and replenishers rarely cross paths.

(410) 305-9766

Multi-Level Pick Modules With Carton Flow Racking

In 32 to 40 foot clear buildings near Dorsey Run and Race Road, a pick module can stack two or three working levels. Each level has a walkway with carton flow racking facing it and replenishment lanes behind.

Conveyor runs along the face to take finished totes away. Pickers move down a short run of lanes instead of across the building.

The design has to account for the walkway decks, stairs and conveyor together, so we draw the whole module, not just the lanes.

Hardware items with long, thin boxes need wider dividers so they do not twist in the lane. We check those during design with a sample box from your shelves.

Carton flow rack with gravity wheel beds and case lanes

Carton flow shelving in use on a warehouse pick line

Lane Design for Mixed E-Commerce Items

E-commerce inventory mixes rigid cartons, polybags and odd shapes. Rigid cartons roll on wheel rails. Polybags and loose items go into totes, which roll consistently.

Lane width is set by the widest container, and dividers keep each SKU in line. Pitch is set for the lightest item on the shelf.

We also check how pickers reach the deepest point of each shelf. If the face sits too far back behind a conveyor, a picker strains every time. Small details like that decide whether the module feels easy after a full shift.

Hardware Distribution and Case Flow Rack

Hardware distributors near National Business Park pick fasteners, fixtures and tools by the case or inner pack. A case flow rack at ground level is often enough there, with reserve pallets on beams above.

Heavy cases of fasteners need stronger wheels and braking; we keep them on their own shelves.

Assigning SKUs by Velocity

We sort your SKUs by picks on the busiest days. The busiest get the golden zone, roughly waist to shoulder, sometimes with two or three lanes. Slower SKUs move to upper or lower shelves or to static shelving.

Revisit assignments as the catalog changes. A seasonal SKU in a prime lane all year wastes the best real estate in the building.

Adding Carton Flow Rack to Existing Rack

If selective rack is already in place, flow shelves slot into the bottom beam positions of the bays you own. Photograph a frame and its connector, and we will pair the parts.

Reserve that must rotate fits a Hanover pallet flow layout. Deep reserve of a few SKUs fits pushback rack in Hanover.

Replenishment Aisles in a Tall Module

Each working level of the module needs its own restock path. On upper levels, cases come up by lift or conveyor and are loaded from a rear walkway.

We size those walkways for carts and keep them separate from the pick walkways. Mixing the two slows both crews.

At ground level, pallet jacks can reach the rear of the carton flow rack directly from reserve. The drawing shows how product travels from the dock to reserve to lane to tote.

Starting a Hanover Pick Module

As a division of Warehouse Equipment & Supplies Co., our team relies on supplying and installing rack since 1997.

Review the carton flow rack page and the Hanover service area page, then send your SKU velocity and container sizes. We return a free layout for the carton flow racking and the surrounding module.

Call (410) 305-9766