Will a Tradepoint Atlantic pick module with several levels use carton flow?

Yes. Each level faces flow lanes, with conveyor and replenishment behind. We draw decks, stairs, conveyor and lanes together.

How do you decide which SKUs go into carton flow in a large catalog?

From pick history. The small share of SKUs that drive most picks get flow lanes in the golden zone; the long tail goes to shelving or higher levels.

What about polybags and loose items?

Put them in totes, which roll consistently. Return lanes carry empty totes back to the restock side.

Do you install carton flow at Sparrows Point?

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

Carton Flow Rack system inside a Maryland warehouse

Sparrows Point, Maryland

Carton Flow Rack in Sparrows Point, Maryland

Carton flow rack in Sparrows Point is mostly about the large e-commerce and import distribution buildings at Tradepoint Atlantic, where thousands of SKUs have to be picked by the each or case.

Gravity lanes bring each SKU to a fixed face; replenishment loads from a dedicated aisle behind.

(410) 305-9766

Pick Modules and Carton Flow Racking at Scale

In 32 to 40 foot clear buildings, a pick module can run several working levels high. Each level faces a wall of carton flow racking, with conveyor carrying totes away and replenishment lanes behind.

The module is a system: decks, stairs, conveyor and flow lanes are drawn together so pickers, restockers and product all have clear paths.

A practical starting point for many big-box tenants is one carton flow rack zone for the fastest few hundred SKUs, with a second zone added as slotting data builds up. The first case flow rack zone usually goes nearest the packing stations.

Bethlehem Boulevard access also shapes where inbound reserve should sit relative to the module.

Carton flow rack with gravity wheel beds and case lanes

Carton flow shelving in use on a warehouse pick line

Velocity Slotting for Large Catalogs

Big catalogs follow a pattern: a small share of SKUs drive most picks. Those go into flow lanes at the golden zone. The long tail sits in static shelving or higher levels.

We slot from your pick history, then plan how often slotting gets revisited. Leaving a slow SKU in a prime lane wastes the busiest real estate in the building.

Pickers in large buildings also need short walks to water, restrooms and break areas, which affects where the module sits. We note those in the layout because a module placed far from them loses time every shift, especially in summer heat.

Case Flow Rack Lanes for Import Freight

Freight arriving by ship or rail at Tradepoint Atlantic is often palletized imports that ship out by the case. A case flow rack line near the reserve area turns those pallets into pickable faces.

Lane width follows the widest carton, with dividers. Imported cartons vary in stiffness, so track type is checked with samples.

Totes, Polybags and Odd Shapes

E-commerce inventory includes items that do not roll on their own. Polybags, small loose items and odd shapes go into totes, which roll consistently.

Return lanes for empty totes keep the module tidy.

Adding Carton Flow Rack Beneath Reserve

Existing selective bays can hold flow shelves near the floor and reserve pallets higher up. One image of a frame and its connector lets us verify parts.

Reserve that must rotate fits a Sparrows Point pallet flow layout. Deep import runs of a few SKUs fit pushback rack in Sparrows Point.

Installing in Large Buildings Near Edgemere

Large non-air-conditioned buildings get hot in summer, which affects crew scheduling. We plan installation by zone and stage material near each zone, with access from Bethlehem Boulevard and I-695 considered for deliveries.

Replenishment Paths in Big Boxes

In buildings this large, the replenishment path can be longer than the pick path. Placing reserve directly behind the module keeps restock trips short.

We draw the dock, reserve and module as one flow so product moves forward without backtracking.

Starting a Sparrows Point Project

Baltimore Pallet Racks is a division of Warehouse Equipment & Supplies Co.; that company has supplied and installed rack since 1997.

Look through the carton flow rack product page plus the Sparrows Point service area page. Send pick history and container sizes for a free carton flow racking layout.

Call (410) 305-9766