American Surplus logo
800-876-3736

Used Flow Racks for FIFO Inventory Systems

Multi-level carton flow rack system with yellow roller tracks and blue uprights, designed for FIFO inventory management in warehouse storage applications

Optimize Space and Efficiency with Gravity-Driven Flow Racks

  • Converts selective pallet racking into a gravity flow system for improved efficiency.
  • Maximizes warehouse space with high-density storage capability.
  • Modular design accommodates a wide variety of materials and product types.
  • Interested in selling your used flow racks? Learn More About Our Purchasing Program
Used Carton Flow Rack
Used Carton Flow Rack
  • Better Organization
  • Quicker Picking Times
  • Reduce Labor Cost
  • Accurate Inventory Control
 View Inventory
Used SpanTrack - Carton Flow Rollers
Used SpanTrack - Carton Flow Rollers
  • Increased Visibility
  • Efficient Use of Space
  • Reduce Labor Cost
  • Easy Reconfiguration
 View Inventory
Used SpanTrack - Carton Flow Beds
Used SpanTrack - Carton Flow Beds
  • Selec Deck Case Flow
  • Dura-Flow by Unarco
  • SpanTrack Wheel Bed
  • Minimal Maintenance
 View Inventory
Used Pallet Flow Rack
Used Pallet Flow Rack
  • Gravity Flow Rack
  • 2-15 Pallets Deep
  • Single or Double Wheel
  • Saves Time, Space, and Labor
 View Inventory
Used Pallet Flow Rails
Used Pallet Flow Rails
  • Single & Double Rollers
  • Install on Selective Rack
  • Includes Brake Assembly
  • Ideal for High-Volume
 View Inventory
Used Mobile Gravity Flow Rack
Used Mobile Gravity Flow Rack
  • Mobile Gravity Flow Rack
  • Ideal for FIFO Inventory
  • Flow Rack Carts
  • Increase Productivity
 View Inventory

We Buy Used Warehouse Equipment

Warehouse aisle with pallet racking on the left storing bagged and boxed goods, and cantilever racking on the right holding stacked lumber and sheet materials, with workers visible in the background

Are you moving or liquidating your facility and looking to sell your used warehouse equipment or material? American Surplus Inc. can help! American Surplus Inc. offers a purchasing program for new and used warehouse and material handling equipment. Learn more about our purchasing program online or call our sales office at (800) 876-3736 to get started.

Learn More

About Flow Racks

Flow racks come in four main types: pallet flow, carton flow, skate wheel, and span track. Each type is suited for specific storage applications but operates on the same core principle—using gravity to move products from the rear to the front of the system through integrated rollers or wheels. These systems are designed for facilities that follow a first in, first out (FIFO) inventory method.

Pallet Flow Rack

Pallet flow systems use inclined rails with skate wheels to allow palletized inventory to move forward as front pallets are removed. This setup maximizes space and is ideal for high-density storage of uniform pallet loads.

Carton Flow Rack

Similar in function to pallet flow, carton flow rack is designed for smaller, lighter products. It is commonly used in picking operations and allows for efficient stock rotation and improved visibility of individual SKUs.

Skate Wheel Flow Rack

Skate wheel systems provide more flexibility than pallet or carton flow. They can accommodate a variety of box sizes and weights, making them suitable for mixed inventory and variable packaging formats.

Span Track Rack

Span track uses rollers instead of wheels and is designed for heavier or denser inventory. Like skate wheel systems, span track is versatile but offers additional load capacity and durability.

Dynamic System Considerations

All flow racks are considered dynamic systems—they are loaded from the rear and picked from the front. This improves picking efficiency and reduces forklift congestion in active areas. However, flow rack systems typically require more aisle space compared to static racking, which is accessed from a single side.

Need help choosing the right flow rack system?
Contact our sales team for expert guidance. We’ll help evaluate your facility layout, inventory type, and throughput goals to recommend the best solution for your operation.

Advantages of Flow Racks

Flow racks, also known as gravity flow racks or carton flow racks, are a type of material handling system designed to optimize storage and order picking processes in warehouses, distribution centers, and manufacturing facilities. Here are some of the key advantages of using flow racks:

  • Improved Order Picking Efficiency: Flow racks operate on a first-in, first-out (FIFO) system. Products are loaded from the rear and flow forward to the picking side, reducing picker travel time and supporting faster, more accurate fulfillment. 
  • Maximized Storage Density: By leveraging vertical space and deep lane storage, flow racks support high-density storage configurations. This is especially valuable in facilities with limited floor space or tall ceilings. 
  • Reduced Labor Costs: With items positioned at the front of the rack, pickers spend less time locating products. This results in fewer labor hours required for picking tasks and contributes to overall cost savings. 
  • Better Inventory Rotation: The FIFO design ensures that older stock is used first, helping reduce product expiration, obsolescence, or overstocking of newer inventory. 
  • Improved Ergonomics: Flow racks present products at the front edge of the lane, which reduces reaching and bending. This minimizes physical strain and supports safer, more ergonomic workflows for warehouse staff.
  • Reduced Product Damage: Because items are moved via rollers or wheels instead of being manually handled or stacked, flow racks help lower the risk of product damage during storage and retrieval.
  • Versatility and Customization: Flow racks can be tailored to handle a wide range of product types, sizes, and weights. They are available in different formats, such as carton flow, pallet flow, skate wheel, and span track systems.
  • Quick Installation and Adaptability: Most flow rack systems are modular and easy to install. They can be reconfigured as inventory or layout requirements change, making them ideal for dynamic warehouse environments.
  • Efficient Stock Rotation: By ensuring older inventory is always at the picking face, flow racks support consistent stock rotation and reduce the risk of outdated or expired goods remaining in storage.
  • Automation Compatibility: Flow racks integrate well with automated systems, such as conveyors, pick-to-light systems, or automated guided vehicles (AGVs), further improving order throughput and minimizing manual handling.

Flow Racks Applications

Flow racks are versatile material handling solutions that find application in various industries and environments. Some of the common applications for flow racks include:

  • Order Picking: Widely used in warehouses and fulfillment centers to streamline order picking. The FIFO configuration ensures that older inventory is picked first, improving accuracy and reducing waste.
  • Assembly Lines: Used in manufacturing facilities to deliver parts and components to assembly stations in a steady, organized manner.
  • Retail Store Replenishment: Used in retail stockrooms to organize backstock and make shelf restocking faster and more efficient for store personnel. 
  • Cold Storage and Food Distribution: In temperature-controlled environments, flow racks support proper rotation of perishable items such as produce, dairy, and frozen goods. 
  • Automotive Manufacturing: Common in automotive plants to stage components like trim parts, fasteners, or electrical units for use on the production line. 
  • Pharmaceutical and Healthcare: Flow racks are suitable for pharmaceutical distribution centers and healthcare facilities, ensuring proper handling and rotation of medical supplies and pharmaceutical products.
  • Electronics Manufacturing: Ideal for delivering circuit boards, wiring, and other small components to workstations efficiently.
  • Textile and Apparel Industry: Used to manage garments and soft goods in fulfillment operations where speed and SKU organization are critical.
  • Automated Warehouses: Compatible with conveyor systems and robotics, flow racks integrate well into fully or semi-automated facilities. 
  • Small Parts Storage: Ideal for organizing hardware items such as screws, bolts, and components in workshops and manufacturing environments.
  • Tool Cribs: Helps organize frequently used tools and supplies for quick access by maintenance or production staff.
  • Kanban and JIT Systems: Often integrated into lean manufacturing workflows to support just-in-time inventory systems and reduce on-hand waste.
  • Beverage Distribution: Helps organize and store high-volume SKUs such as bottled and canned beverages for efficient picking and rotation.
  • Aerospace Industry: Used to stage precision components, fasteners, and materials for aircraft assembly and sub-assembly stations. 

Flow Racks Manufacturers

  • UNEX Manufacturing, Inc.
  • Span-Track by UNEX
  • Flexpipe
  • Mallard Manufacturing Corporation
  • FlexQube
  • Interroll Group
  • Bastian Solutions
  • Hy-Tek Material Handling, Inc.
  • Frazier Industrial Company
  • Creform Corporation

Other Names for Flow Racks

  • Gravity Flow Racks
  • Carton Flow Racks
  • Roller Racks
  • Flow Shelving
  • Dynamic Racks
  • FIFO Racks (First-In-First-Out)
  • Live Storage Racks
  • Carton Live Storage
  • Gravity Flow Shelving
  • Case Flow Racks
  • Flow Through Racks
  • Pick-to-Light Racks
  • Pallet Flow Racks
  • Dynamic Storage Racks
  • Gravity Feed Racks

Flow Rack Frequently Asked Questions

Q: How does a flow rack work?
A: Flow racks use the principle of gravity to move products. Products are loaded onto the higher end of the rack, and due to the slope of the rollers or conveyor lanes, they move downward toward the picking end. This ensures that the oldest products are automatically presented for picking, promoting first-in, first-out (FIFO) inventory management.

Q: What types of products are suitable for flow racks?
A: Flow racks are ideal for products with a high turnover rate or those that need to be picked quickly and efficiently. They are commonly used for small to medium-sized items in various industries, including retail, automotive, pharmaceuticals, and food and beverage.

Q: How do I maintain a flow rack system?
A: Regular maintenance is essential to keep a flow rack system functioning optimally. This includes inspecting and lubricating rollers or conveyor lanes, ensuring that flow lanes are clear and free of obstructions, and addressing any damaged or worn components promptly.

Q: What safety measures should be in place when using flow racks?
A: Safety measures for using flow racks include providing proper training to employees who operate them, ensuring clear access to emergency shut-off controls, and implementing safety guardrails or barriers to prevent accidents.

Q: Can flow racks be combined with other types of storage systems?
A: Yes, flow racks can be integrated with other storage systems such as pallet racks, shelving units, and mezzanines to create a comprehensive and efficient storage solution that suits the specific needs of the facility.

Q: What are the cost considerations when implementing a flow rack system?
A: The cost of implementing a flow rack system depends on factors like system size, complexity, customization, and the type of products being stored. While there is an initial investment, the efficiency gains and improved inventory management often result in a favorable return on investment (ROI).