Ten tips from the UK on to improve pallet flow when time and space is at a premium
 Here are 10 tips from the United Kingdom on optimising pallet flow to maximise productivity, extend equipment life and improve safety.
TIP No 1: When it comes to pallet racking, flow storage is essential for managing perishable, time-sensitive products on a first in, first out (FIFO) basis, says London's Logistics Handling journal, whence these tips come.
TIP NO 2: Since its design eliminates aisles and fills the space with additional pallets, it provides many times more storage than selective rack. In addition, forklift travel is greatly reduced because drivers only need to place and retrieve loads from either end of the system - significantly reducing operating costs, maintenance, and accidents.
Better space utilisation also minimises the need to light, heat and cool the facility, further decreasing expenses.
TIP No 3: Consider flow storage when efficient storage is critical and space limited.
Flow storage is useful in many applications including ambient, cooler, and freezer environments, raw materials receiving and storage, work-in-process, buffer storage, finished goods and cross docking. It is also often successfully used in pick module and automatic storage and retrieval systems (AS/RS).
Understand how flow storage works. Unlike traditional selective rack, a pallet flow storage system has two parts: a static rack structure and dynamic flow rails. The flow rails are set at an incline in the rack structure, which allows loads placed on one end of the rack to move by gravity down to the unloading end.
Rollers let the loads move smoothly while self-energised speed controllers act as gentle brakes. As a load is removed, the loads behind it move forward automatically.
TIP No 4: Choose a design that can adapt to both current and future needs. Because budget and inventory requirements change at both the facility and corporate level, it is wise to select a flow system with a design that can grow as your business needs grow.
“With flow systems, bays can be added to groups and the bay widths and depths can be easily be expanded to hold additional inventory, which allows you to buy for your current needs and expand later,” says Steel King Industries sales manager Ryan Wachsmuth.
Ensure that the flow storage system has enough rack strength. To be even more accommodating of future needs, such as higher or heavier pallets, also select a flow system that provides vertically adjustable beams and ample strength.
You can always re-profile your flow rack to handle higher, heavier pallets if you design for it. If you use a 48” high pallet today, but decide later that a 60” high pallet is more efficient because you want to add two more levels of ice cream to each pallet. A system with vertically adjustable beams would allow that, provided adequate rack strength.
TIP No 5: When you design your flow storage system, you have to know your warehouse’s capabilities and limitations. For instance, know how low girders, trusses, warehouse lighting, HVAC ductwork, and sprinklers and fire suppression lines hang to determine adequate clearance.
Before beginning it is necessary to consult with fire official and get approval on the design and layout to ensure it meets fire code standards.
TIP No 6: Plan for expected flow system use. If your warehouse is heavily used, forklift drivers are more prone to impact racking. Because a flow system’s entry uprights tend to receive the most damage from forklifts. Thus it is wise to work with vendors offering reinforced upright options.
Guardrail, rack and column protectors, as well as weld bumpers (angles welded to the aisle side beams), can also help to protect the pallet flow rack system from forklifts. If impact occurs, these safety items can be quickly replaced without having to close off lanes or bays.
Facilities should also consider holding extra rack inventory, such as uprights and beams, so any rack damage can be repaired immediately. This keeps production going without waiting for a supplier to ship replacement parts.
TIP No 7: Consider facility requirements and standards. For industries whose products require high hygienic standards, such as for food, dairy, beverage or pharmaceutical products, it is important to avoid any racking with holes, open spaces, or flat spots where food or liquid can accumulate, potentially leading to rot, mould or other contamination.
To meet regulatory requirements that flow systems use a sanitary structural channel rack design. As an example, acquire angled tubular cross bracing. The angled surfaces and closed tubular construction leads food or liquid that falls on the rack to flow off, thus preventing potential hygienic or contamination issues.
TIP No 8: Ask for a pawl anti-backup device to ensure safe unloading and proper flow. When forklift drivers unload a pallet from the flow system discharge end, they typically perform a maneuver called a "plug". That is, with the pallet they pick up, they push the next pallet in the flow lane to get the row of pallets to properly flow to the unloading end.
When forklift drivers perform this standard maneouver, a pawl anti-backup device can help prevent a pallet from unintentionally being pushed off the loading end. A pawl can also assist productivity by helping forklift drivers keep pallets safely flowing to the unloading end of the system.
TIP No 9: Seek single source accountability. Designing and installing a pallet flow system could involve a separate pallet flow manufacturer, a rack manufacturer, as well as a dealer and installer. However, this type of setup is not recommended by experts due to the significant coordination required from each of these independent parties to resolve any issues.
TIP No 10: The vendor should perform a "full test" of the system, including rail type, rail pitch, brake spacing, as well as a full pallet test to ensure it fits your pallet, product, and workflow. Successful flow systems are the result of proper design and thorough testing of all the related components. There are many variables to a flow system, and even hundreds of pallet variations, such as wood, plastic, metal, and bottom boards running parallel or perpendicular, all of which can affect flow. |
