What is carton flow rack actually used for?

Case and piece picking. Cartons ride gravity wheel beds so the next unit advances to the pick face automatically, cutting walking time and keeping the line organized as SKU counts climb.

How is it different from static shelving?

On static shelving, a picker reaches into the bay and someone has to physically face the product afterward. Carton flow feeds from behind and presents at the front, so rotation is automatic and the pick position never moves.

Can soft or lightweight cartons run on carton flow shelving?

Full-width wheel beds handle mixed and flimsy cartons far better than spaced roller tracks. If your cases vary in stiffness, that's the specification we'll recommend, and we test travel with your actual cartons at installation.

Can carton flow drop into racking we already own?

Frequently. Wheel beds and track can go into existing bays when frame depth and beam spacing allow it. We verify your current profile first and convert only the bays that fit.

Can a Merced carton flow rack project be phased around food processing operations near State Route 140?

Merced connects agricultural and manufacturing supply with north-south freight on Route 99. Mission Avenue facilities can handle both incoming production material and outgoing orders, making the reserve-to-dispatch relationship an important part of rack planning. Agree the work zones, inventory transfers, access windows, and handover sequence before starting. Phasing is evaluated against your current storage needs and site conditions; uninterrupted operation and a particular completion date cannot be assumed until the scope and approvals are known.

Carton Flow Rack warehouse storage system

Merced, California

Carton Flow Rack in Merced, CA

Merced order fulfillment teams handling case picks need stock presented consistently across the shift. Carton flow uses assigned lanes so replenishment supports the pick face instead of forcing staff to search deeper into static shelves. Merced connects agricultural and manufacturing supply with north-south freight on Route 99. Mission Avenue facilities can handle both incoming production material and outgoing orders, making the reserve-to-dispatch relationship an important part of rack planning. Carton Flow Rack in Merced, CA starts with case presentation at a fixed pick face with replenishment kept behind the rack. We review carton dimensions, base stiffness, case weight, picks per shift, and rear replenishment access before recommending a configuration.

You get a free design consultation, a CAD plan, and an itemized quote for your actual building, not an assumed warehouse footprint. Carton flow stores cases, not full pallets. Reserve pallets above a pick area require a separately rated and reviewed rack configuration. Call (559) 620-5206 to discuss the constraint that is holding up your next receipt or order.

(559) 620-5206

Why Merced Warehouses Work With Us

Merced connects agricultural and manufacturing supply with north-south freight on Route 99. Mission Avenue facilities can handle both incoming production material and outgoing orders, making the reserve-to-dispatch relationship an important part of rack planning. Check the receiving window against the quantity of reserve stock that must stay accessible. A Merced layout should leave a workable shipping buffer and distinguish frequently picked materials from bulk stock that can remain behind fewer access faces.

For carton flow rack, that means checking carton dimensions, base stiffness, case weight, picks per shift, and rear replenishment access against the way your Merced team actually works. Carton flow stores cases, not full pallets. Reserve pallets above a pick area require a separately rated and reviewed rack configuration. We compare the storage arrangement with the receiving, production, and dispatch space it leaves available, so a higher count does not come at the expense of daily access.

Fresno Pallet Racks connects your project with Warehouse Equipment & Supplies Co.. You can discuss the Merced plan with one contact, ask for a revised layout, and see the scope in writing before ordering. A free design consultation should explain both the benefit and the tradeoff of carton flow rack; it should not pressure you into a system that mismatches your inventory. Installation timing and any later additions are planned around the actual site and approved configuration.

Free warehouse consultation

CAD layout with position counts

Installation by trusted installation partners

Carton flow rack with gravity wheel beds and case lanes

Carton flow shelving in use on a warehouse pick line

Operations We Rack Around Here

Local industrial and transport corridors include State Route 99, State Route 140, Mission Avenue.

Food processing

Agricultural distribution

Light manufacturing

How Carton Flow Rack Works

Cases advance to the picker instead of the picker hunting for cases.

Inclined wheel beds

A full-width wheel bed or roller track sits on a slight incline inside a standard bay, so cases move forward under their own weight without power.

Pick from a fixed position

The picker always reaches for the same forward spot in the lane. Travel time drops, and so does the time spent searching for the next case.

Restock from behind

Replenishment loads the high end of the lane from a separate aisle, so restocking never blocks or slows the pick line, and rotation stays first in, first out automatically.

One lane per SKU

Lane dividers set the width for each case size, giving every SKU its own face - a width that can be resized as your product mix shifts.

What a Carton Flow Rack Project Includes

Your Merced carton flow rack project starts with a practical inventory and building review. We collect carton dimensions, base stiffness, case weight, picks per shift, and rear replenishment access, usable ceiling height, column locations, door positions, and the current traffic pattern. Check the receiving window against the quantity of reserve stock that must stay accessible. A Merced layout should leave a workable shipping buffer and distinguish frequently picked materials from bulk stock that can remain behind fewer access faces. Photos and an existing drawing help start the conversation; dimensions and conditions must be confirmed before an installation plan is finalized.

The CAD layout shows the storage arrangement, operating aisles, level or lane elevations, and the usable position count. We review case presentation at a fixed pick face with replenishment kept behind the rack against an alternative where a comparison helps. The itemized quote identifies the system components, specified capacities, protection, and installation scope. Our team handles the permit side for you.

Delivery and work zones are planned around the access at your State Route 99 or State Route 140 building. Installation follows the approved configuration, with frames or bases anchored as specified, connections checked, and alignment verified. Systems with moving carts, rollers, or wheel beds are checked with representative loads. Carton flow stores cases, not full pallets. Reserve pallets above a pick area require a separately rated and reviewed rack configuration. Your team receives the agreed configuration and capacity information, a layout to use for later changes, and a clear contact for follow-up questions. Do not change elevations or loads without checking whether the ratings and approvals still apply.

Case and each picking operations

Order fulfillment lines carrying many active SKUs

Grocery, beverage, and consumer goods distribution

Kitting and light assembly feed lines

Bays that need reserve pallets stacked above the pick face

Call (559) 620-5206

Recent Installations

Racking projects completed for warehouses across Fresno and the Central Valley.

View More Projects

Get a Carton Flow Rack Quote for Your Merced Warehouse

Send the basics and we will follow up with a layout and pricing. Prefer to talk it through? Call (559) 620-5206.

Fresno Pallet Racks

5730 N First St

Ste 105 #252

Fresno, CA 93710

(559) 620-5206

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

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