Pallet Flow Rack in Sparrows Point, Maryland

In large buildings, a fraction of SKUs drives most pallet movement. Pallet flow racking gives those items deep lanes with a constant pick face.

Replenishment and picking happen in separate aisles, which matters when dozens of trucks move at once.

Start with a slotting review using a few weeks of shipping data. It shows which SKUs truly move fastest, and those earn the deepest lanes and the positions closest to the outbound doors.

Revisit slotting each quarter, since a large catalog changes faster than most teams expect and lanes drift out of balance.

Small reviews prevent big resets.

Buildings at 32 to 40 feet clear can hold many flow levels. Each level adds positions without adding floor.

Lanes rise toward the load end, so upper levels need truck reach checks at that end.

With deep-water berths and CSX / Norfolk Southern rail access, inbound arrives in large lots. Flow lanes keep each lot behind the previous one, so older freight leaves first.

Large systems carry pallets of many weights. Grouping similar weights into lanes keeps brakes and slope working properly. A gravity flow rack with speed controllers and exit separators protects pallets and operators.

At this scale, a pallet program matters: one pallet type for flow lanes, inspection at receiving, and a re-palletizing station for odd loads. Jams in a large system cost real time.

Summer heat in large non-air-conditioned buildings affects crew scheduling. We plan installation by zone with material staged near each one, considering Bethlehem Boulevard and I-695 access for deliveries.

Undated reserve fits pushback rack in Sparrows Point. Each and case picking of slower SKUs fits carton flow rack in Sparrows Point in a pick module.

Big systems need a maintenance routine. Assign someone to walk each pallet flow rack aisle weekly, checking rollers, brakes and separators, and log what they find.

Keep spare parts on site. In a building this size, waiting for a replacement roller can leave lanes out of service longer than necessary.

Fit guides where pallets enter and guards where they leave. A gravity flow rack with hundreds of lanes sees a lot of forklift traffic, and the ends take most of the impacts.

Train every driver on square loading at the entry. Crooked pallets are the most common cause of slow lanes.

Clear lane labels at both ends keep receiving and picking aligned, especially when several customers share the building.

Large tenants at Tradepoint Atlantic often grow in phases. Building the first phase with standard frame depths and lane lengths lets later phases match.

We keep the layout on file so the next phase starts from the existing plan and fits alongside it.

That approach also helps when inbound volume shifts between ship, rail and truck.

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

Review the Sparrows Point service area page and the pallet flow rack product guide. Tell us SKU velocity and pallet specs, and our team will draft your pallet flow racking free.

Baltimore Pallet Racks

1400 W. Lombard St.

Unit #687

Baltimore, MD 21223

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

Is pallet flow rack worth it for high-volume SKUs at Tradepoint Atlantic?

How many flow levels fit a 36-foot building?

How do you prevent jams in a large flow system?

Do you install pallet flow at Sparrows Point?