Carton Flow Rack in White Marsh, Maryland

Retail distributors building store orders pick many cases of a moderate number of SKUs. Carton flow racking puts those SKUs in a short, dense face so pickers build orders without long walks.

Because restocking happens behind, the face stays full through the shift.

Fulfillment teams along MD-43 also use a short line of flow lanes at packing stations for boxes, tape and filler. Packers pull from the front, and supplies are restocked from behind without interrupting them.

Simple habits like that keep a pick line running smoothly for years, even as the product mix shifts.

Many White Marsh buildings run two shifts. A common split: the night shift replenishes from the back aisle, the day shift picks from the front. The rack keeps the two crews apart.

Labels on each lane front let either shift confirm the SKU at a glance.

Retail cartons sometimes change size when a vendor changes packaging. When that happens, check the lane width and track type for the new carton before loading it. A box that is slightly wider than the old one can jam a lane that worked fine for years. Labels showing the expected case size on each lane front make those changes easy to spot.

Retail cartons are mostly corrugated with flat bottoms, which run well on wheel rails. Shrink-wrapped multipacks and soft cases need full roller beds.

Each case flow rack lane is sized to its widest carton, with dividers holding it straight. Shelves group items of similar weight so pitch suits everything on them.

Building-products distributors near Nottingham and Pulaski Highway also pick by the case: fittings, fasteners, small tools. Heavy cases get stronger wheels and speed control on their own shelves.

Retail peaks change what is fast. Before peak, we move seasonal SKUs into prime carton flow rack lanes and bump slower ones to static shelving. After peak, they swap back.

Designing a few spare lanes into the module makes those swaps easier.

Newer bulk buildings with existing selective rack can usually take flow shelves at the lower levels, with reserve pallets above. An image of one frame and its connector lets us confirm.

Reserve that must rotate fits a White Marsh pallet flow system. Several like pallets per SKU belong in pushback rack in White Marsh.

Newer bulk buildings near Campbell Boulevard can stack flow lanes into a pick module with two or more working levels. Conveyor along each level carries totes to packing.

Each level needs its own restock path at the rear. We draw decks, stairs, conveyor and lanes together so the module works as one system.

In older, shorter buildings along Pulaski Highway, a single-level line with reserve above is usually the better fit.

We are a division of Warehouse Equipment & Supplies Co., the parent company supplying and installing rack since 1997.

Read the carton flow rack overview and the White Marsh service area page, then send SKU picks and carton sizes for a free carton flow racking layout.

Baltimore Pallet Racks

1400 W. Lombard St.

Unit #687

Baltimore, MD 21223

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

Does carton flow speed up store-order picking in White Marsh?

Can night-shift restocking and day-shift picking work on the same carton flow?

How do you handle seasonal peaks in carton flow lanes?

Will shrink-wrapped multipacks roll on carton flow?