How does gravity flow racking compare to static shelving for order picking?

Gravity flow racking typically provides faster picking than static shelving because products are always presented at the front face, workers walk less between picks, and search time is reduced with clear product visibility. Automatic stock rotation eliminates manual rotation tasks, and keeping items at a convenient picking height improves ergonomics, so most operations pick significantly faster with fewer errors and less worker fatigue.

What types of products work best with gravity flow rack systems?

Gravity flow rack systems are ideal for containerized items with consistent dimensions such as boxed products, totes, cases, and palletized goods. Items with flat bottoms and enough weight to roll smoothly work especially well, and products that benefit from FIFO inventory management gain the most from gravity-based flow.

Can gravity flow racks be integrated with existing warehouse systems?

Yes. Span track and carton flow systems can fit directly into standard pallet racks, and standalone gravity flow units can replace static shelving sections. Gravity flow racks also integrate well with pick-to-light technology and warehouse management software, allowing you to upgrade existing layouts while adding gravity flow benefits.

Can gravity flow racks be customized for different SKUs or warehouse layouts?

Yes. Carton flow racks offer adjustable trays and lane dividers for boxes or totes of varying sizes, and pallet flow racks can be configured for different lane depths, weight capacities, and brake setups. Systems are scalable and can be installed in phases to match your SKU mix, space constraints, and budget.

How do gravity pallet flow racks prevent pallets from moving too quickly?

Gravity pallet flow racks use built-in speed controllers and brake rollers that slow pallets as they advance. These components keep pallet movement controlled and help prevent product damage or unsafe collisions at the pick face.

What should I consider before installing gravity flow systems?

Before installing gravity flow racks, verify that you have proper slope, level flooring, and clear access aisles on both loading and picking sides. Pallet flow lanes must be designed with appropriate brake spacing and load ratings. Southwest Solutions Group can review your space, inventory, and existing racking to design and install a system that fits your footprint.

Gravity Flow Racks for High-Density Warehouse Storage

Gravity flow racks give warehouses, distribution centers, manufacturers, and e-commerce operations a simple way to increase storage density and keep product moving in a true first-in, first-out sequence. By combining sloped roller lanes with separated loading and picking aisles, these systems reduce travel time, errors, and congestion on the floor. Use gravity flow racks as stand-alone carton flow, deep-lane pallet flow, or integrated with mobile systems to reclaim space without expanding your footprint. You can download Revit files to plug into your layouts or request a consultation with Southwest Solutions Group for help designing the right gravity flow rack configuration.

Push back rack storage system with angled shelves for high-density pallet storage and easy retrieval

How Gravity Flow Systems Work

Gravity flow racks use sloped roller tracks to move products from the loading side to the picking side — no motors or power required. Items are loaded in the back and automatically roll to the front, creating a true first-in, first-out (FIFO) flow. This passive movement keeps picking operations fast and efficient.

By separating loading and picking zones, these racks eliminate congestion while ensuring older inventory is used first. The consistent front-facing product layout also reduces pick time and walking distance.

Benefits include:

Passive gravity-based movement
FIFO rotation keeps oldest stock forward
Separate loading and picking aisles
Sloped rollers for continuous product flow
Ideal for warehouses, DCs, and retail backrooms

Options for Every Product Type

Different rack configurations are available depending on product size, weight, and packaging. Carton flow racks feature sloped shelves for lightweight boxes and totes, while pallet flow racks handle heavier loads with deep-lane storage.

Carton flow shelves can be adjusted to hold boxes of different sizes and support 50–100 lbs per square foot. For pallets, gravity-fed lanes store 2–10 pallets deep and include brakes to prevent over-speeding.

Benefits include:

Carton flow for boxed inventory
Pallet flow racks for high-weight goods
Depth-based storage from 2–10 pallets deep
Adjustable lanes for mixed SKUs
Brakes and guides for pallet control

Gravity flow racks installed in a high-density warehouse for organized inventory and space saving

Gravity flow racking system for storing and picking boxed inventory in a warehouse environment

Boost Storage Density Without Expansion

Mobile wide span racks mount to rail systems that eliminate fixed aisles, increasing storage density without sacrificing access. Carriages are controlled by mechanical-assist handles or powered systems and include locking features for safety.

Benefits include:

Reduces aisle space between rows
Multi-level storage maximizes vertical capacity
Stores 3–4x more inventory than static shelving
Consolidates operations into a smaller footprint
Creates room for other warehouse processes

Carton flow gravity rack system designed for efficient picking and storage of boxes and items — Maximize picking speed and inventory accuracy with FIFO rack flow.

Distribution centers depend on rapid, accurate order picking to meet tight shipping commitments. Gravity flow racks create organized, high-density pick zones where cartons or cases automatically move from the loading side to the picking side, so associates always find product at the aisle face.

By combining gravity flow racks with barcode or pick-to-light technology, DCs reduce walking time, minimize search, and keep workers in productive zones. True FIFO rotation also helps prevent hidden, outdated stock from sitting in the back of the rack.

FIFO rotation ensures inventory accuracy
Reduces walking and pick time
Integrates with pick-to-light and WMS
Dual aisle layout prevents bottlenecks
Increases pick rates without expansion

Lean manufacturing lines run best when the right parts are always at hand. Gravity flow racks feed components, kits, and subassemblies to the front of workstations so operators can pick quickly without leaving the cell or calling for replenishment.

These gravity flow rack systems are ideal in kitting areas and point-of-use storage, where high-frequency items need to move automatically toward the operator. As parts are removed, new inventory rolls forward, keeping production flowing.

Keeps parts stocked at the front
Supports just-in-time assembly
Reduces handling and storage time
Ideal for kitting and staging zones
Improves flow along production lines

Pallet flow rack system for high-density storage and improved inventory rotation in warehouse environments — Store more backstock with fast access and minimal aisle space.

Retail stockrooms are often cramped, high-turn environments. Carton gravity flow racks compress backstock into dense lanes while keeping the oldest product at the front, so employees can quickly find sizes, colors, and styles without digging through mixed boxes.

With front-facing shelves and smooth-rolling lanes, gravity flow racks help grocery, apparel, and general merchandise teams replenish sales floors quickly, even in narrow aisles or small backrooms.

Sloped shelves for boxed goods and totes
Great for fast-moving retail inventory
Improves space use in tight backrooms
Maintains FIFO stock rotation
Easy for staff to access and restock

Warehouse storage solution using gravity flow shelving for faster access to stored inventory — Improve food safety and reduce spoilage with FIFO pallet rotation.

In refrigerated or frozen warehouses, every pallet position is valuable and product rotation is critical. Gravity pallet flow racks automatically bring the oldest loads to the pick face so teams pull in true FIFO order without extra handling or manual rotation.

Because loading occurs in a separate aisle from picking, doors spend less time open and lift trucks move more efficiently in tight, temperature-controlled spaces, lowering energy costs and protecting product quality.

Supports FIFO compliance for perishables
Pallet flow prevents overlooked backstock
Reduces spoilage and product loss
Minimizes door-open time in cold zones
Optimizes space in high-cost environments

Heavy-duty gravity flow shelving system designed for handling heavy and medium loads in a warehouse — Speed up order picking with forward-facing SKUs and dense lanes.

E-commerce fulfillment centers juggle thousands of SKUs and fast-changing order profiles. Carton gravity flow racks present clearly labeled, forward-facing SKUs so batch, wave, or zone pickers can move quickly with fewer errors and less walking.

As items are picked, new cartons automatically roll into position, keeping high-velocity SKUs available at ergonomic heights and shortening training time for seasonal or temporary workers.

Clear, organized product presentation
Supports batch, zone, or wave picking
Lowers training time for new workers
Speeds up fulfillment with less walking
Easy to re-slot for changing SKUs

Frequently Asked Questions

Faster picking with products presented at the front face
Less walking between picks with concentrated storage zones
Reduced search time with clear product visibility
Automatic stock rotation eliminating manual rotation tasks
Better ergonomics with products at convenient picking height

Most operations pick 30–40% faster with gravity flow, with fewer errors and less worker fatigue. The productivity gains quickly pay for the system.

Containerized items with consistent dimensions
Boxed products, totes, cases, and palletized goods
Items with flat bottom surfaces for smooth rolling
Products with sufficient weight to overcome roller friction
Items that benefit from FIFO inventory management

Southwest Solutions Group can assess your inventory to suggest the best setup.

Yes. Span track systems fit directly into standard pallet racks. Standalone gravity flow units can replace static shelving sections. These systems also work well with pick-to-light systems and warehouse software. Southwest Solutions Group specializes in creating solutions that use your existing equipment while adding gravity flow benefits.

Yes. Carton flow systems offer adjustable trays for boxes or totes of varying sizes. Pallet flow racks can be configured for different lane depths, weight ratings, and brake setups. Both systems are scalable and can be installed in phases to meet space or budget constraints.

Pallet flow racks include built-in speed controllers and brake rollers to slow pallets as they advance. These features maintain safe, controlled movement and prevent product damage or unsafe collisions during picking.

Gravity racks require proper slope, level flooring, and clear access on both the loading and picking sides. Pallet flow lanes must be installed with appropriate brake spacing.

Southwest Solutions Group can design and install systems that fit within your existing racking or footprint.

Honest Results

“I wanted to say thank you for all the guys that installed the remaining two active racks this week. They did an outstanding job and we couldn’t have asked for a better group of guys to install. Thanks again to Chester, Bruce, Jay, Donald, and Christopher"

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Southwest Solutions Near You

With 7 offices in Texas, Oklahoma, Kansas and Colorado, plus teams covering every major metro area nationwide, Southwest Solutions Group delivers expert gravity flow rack sales, design, installation, and maintenance support wherever you need it.

Gravity Flow Rack Service Areas

Texas

Offices in Austin, Dallas, Houston & San Antonio w/ sales, design, and installation coverage statewide

Austin
Dallas
El Paso
Fort Worth
Houston
San Antonio

Oklahoma

Office in Edmond w/ sales, design, and installation coverage statewide

Broken Arrow
Edmond
Lawton
Norman
Oklahoma City
Tulsa

Kansas

Office in Lenexa w/ sales, design, and installation coverage statewide

Kansas City
Lawrence
Olathe
Overland Park
Topeka
Wichita

Colorado

Office in Englewood w/ sales, design, and installation coverage statewide

Aurora
Colorado Springs
Denver
Fort Collins
Lakewood
Boulder

Alaska