Flow rack for FIFO - when does the roller lane pay off?
A flow rack uses slightly inclined roller lanes to move containers by gravity from the loading side to the pick face, enforcing FIFO automatically. This guide shows at what throughput the roller lane pays off against static shelving and how to size incline, channel width and brake rollers.
View flow racksHow does a flow rack work and why FIFO?
A flow rack is built from slightly inclined roller or wheel lanes. The operator loads the lane from the higher rear side, and the containers roll forward by gravity to the pick stop at the front. Because new stock always feeds in at the back and picking happens at the front, you get FIFO automatically: First In - First Out.
This separates loading and picking into two aisles. The picker walks only the short pick face instead of hunting for each item deep inside a shelf. That compacts the storage and shortens travel distances noticeably.
When does the roller lane beat a static shelf?
A flow rack costs more per channel than a plain shelf, but it saves floor space and picking time. As a rule of thumb it pays off from medium to high pick frequency and when the same SKU is held in several containers. For slow movers with only one bin per item, static shelving stays cheaper.
- Pays off from roughly 5 or more picks per channel per day, or with several bins per SKU.
- The compact pick face typically halves the picker's travel distance.
- Loading and picking are decoupled - refilling does not disturb the pick front.
- For pure slow movers with a single bin, the static shelf stays more economical.
How to size incline, channel width and brake rollers?
The incline decides whether containers feed forward reliably yet under control. For plastic small-parts bins a gradient of about 3 to 5 % is common (roughly 3 to 5 cm per metre of lane). Too flat and stock stalls, too steep and it runs unbraked and jams at the stop.
The channel width follows from the bin width plus roughly 15 to 25 mm of guidance clearance. Too tight and the bins jam, too wide and they skew and run crooked. Side guide rails keep the bins centred on the lane.
- Wheel lanes for light small-parts bins, roller lanes for heavy or uneven loads.
- Plan brake rollers every 1 to 2 m on channels longer than about 2.5 m.
- A pick stop with retention keeps the front bin standing safely.
- Check the bin base - open mesh bases need a little more incline.
Frequently asked questions
What incline does a flow rack for bins need?
For plastic small-parts bins a gradient of about 3 to 5 % is common, that is 3 to 5 cm per metre. Smooth bases run at a flatter angle, rough or heavy bins need a little more. Always test with the real bin.
What are brake rollers for?
Brake rollers cap the speed of the rolling bins at around 0.3 m/s. That way the front stock arrives gently at the stop instead of slamming into it. Without a brake the load accelerates uncontrolled over the lane length.
When does a flow rack beat a static shelf?
From medium pick frequency, several bins per item and wherever FIFO is mandatory. It saves up to 60 % of floor space and shortens picking travel. For slow movers with a single bin, static shelving stays cheaper.
How wide should a channel be?
Bin width plus about 15 to 25 mm of guidance clearance. Too tight and stock jams, too wide and it skews. Side guides keep the bins centred.
Looking for a FIFO flow rack?
We supply flow racks with wheel and roller lanes including brake rollers and guides - matched to your bins and throughput.
FIFO guaranteed
Separate loading and picking enforce First In - First Out.
Space saved
Compact storage with up to 60 % less floor space.
Gently braked
Brake rollers hold the bins at a safe speed.
Expert advice
We size incline, channel and brakes to your bins.