What are Gravity Flow Racks and How do They Work
Sometimes people use industrial racking not only for storage, but also to bring better efficiency and productivity to the operations in the warehouse. That's why gravity flow racks are increasingly being used in industries where goods need to be accessed and moved frequently.
Now, let's take a look at gravity flow racks from HEDA's perspective as a manufacturer, why they are favored by these industries, and what makes them so special.
What are gravity flow racks？
A gravity flow rack is one of the warehouse racking types that has a unique look and functional design. It is not like the common pallet rack that requires you to move the goods manually, when you deposit the goods into the gravity flow rack, the goods will automatically slide to the take out area of the gravity flow rack.
The composition of gravity flow rack is also different from the traditional rack, gravity flow rack is roughly composed of uprights, beams, tracks, rollers, base plates and bracing and other components. There are some variations in the components of different types of gravity flow racks, so it depends on the type of gravity flow rack you choose.
Gravity flow racks options
The core types of gravity flow racks are mainly carton flow racks and pallet flow racks, which are also the most common and widely used, so we focus on these two types.
Carton Flow Rack
This is a type of gravity flow racks that is specially created for small packaged goods, the main type of goods oriented is cartons, boxes or other types of lightweight goods.
Its appearance is usually composed of multi-level ramp track, carton goods from the top into and automatically slide down to the bottom of the take-out area, the initial goods into the carton flow rack is also the first to slide down to the take-out area, so its inventory management is the use of FIFO.
The advantages of a carton flow rack are also obvious, the main advantages are three: improved picking efficiency, space saving and FIFO inventory management mode.
The carton flow rack is mostly found in e-commerce or FMCG warehouses, where high picking speeds and frequent in and out of the warehouse are required.
Pallet Flow Rack
This is a kind of gravity flow rack specially designed for large or heavy goods, the common form of goods is palletized goods, so we also call it a pallet flow rack.
The appearance and design of the pallet flow rack is similar to the carton flow rack, but the volume of the pallet flow rack will be bigger because of the bigger goods to be stored. Inventory management is also the same as carton flow rack, they both use FIFO inventory management mode.
The advantages of a pallet flow rack are a little different, the main overview is three outstanding advantages: high load capacity, semi-automated access and high space utilization.
Pallet flow racks are mostly found in some industrial warehouses, manufacturing or wholesale distribution warehouses, etc. The common feature of these places is that they store goods with high weight or large volume, and they also need to enter and exit the warehouse frequently.
Customized Gravity Flow Racks
Among the types of racks, no matter what kind of racks can be customized, there are always some problems that can not be solved by the conventional racks, so we have to modify the original racks to meet your storage needs.
The common customization solutions for gravity flow racks are: customize the depth of the rack, you can choose single depth or double depth. The modular design allows for flexible adjustments to gravity flow racks, and there are also options for rack materials, specifications, and exterior colors for you to choose from.
How do gravity flow racks work?
The core working principle of the gravity flow rack is that it relies on the force of gravity to make the goods slide automatically in the rack. In order to realize this principle gravity alone is not sufficient, so specially designed inclined slopes and sliding rails are also important components.
Core Components and Structures
Inclined Tracks
The inclined track is one of the key components of a gravity flow rack, which is typically inclined at an angle of 15°-30°. It is the presence of the inclined track that allows the goods to slide forward under the force of gravity.
Roller System
If only the inclined track is incomplete, a key component is needed for the goods to move smoothly on the track, that is the roller system, which has sliding wheels or rollers that reduce the friction of the goods on the shelves and ensure that the goods can slide smoothly.
Uprights and Beams
uprights and beams in a gravity flow rack system are vertical and horizontal support structures that provide stability and load bearing for the entire rack system.
Workflow of gravity flow rack
Stocking of goods
The first step is to place the goods to be deposited at the back or top of the gravity flow rack system (these areas are usually the deposit areas of the gravity flow rack). The moment the goods are placed in the gravity flow rack, the goods will start to slide slowly and automatically towards the lower part of the rack under the effect of gravity until they meet the resistance of the goods in front of them or at the very front end of the rack to stop sliding.
Movement of goods
As subsequent loads are deposited, the distance over which they can slide becomes shorter and shorter until the aisle is full. Because the first deposited goods will automatically slide to the front, the subsequent goods will slide until they meet the goods in front and then naturally stop sliding.
Goods out
When you pick up a product and remove it from the front or bottom of the gravity flow rack system (these areas are usually the removal areas of the gravity flow rack), the product in the aisle will automatically slide forward to fill in the gaps left by the removed product, and the deposit area will be vacated.
Advantages of gravity flow racks
Increased storage density
The gravity flow rack system's multi-tier ramps make it possible to provide you with higher storage density in warehouses where space is limited.
FIFO Inventory Management
For industries that require strict control over the order in which goods are released from the warehouse, the FIFO inventory management model can help them avoid situations where goods with early deposit deadlines are forgotten, resulting in expiration dates.
Improve operational efficiency
Because of the automatic forward sliding function of the gravity flow rack, staff only need to move in a fixed area to access the goods, and the movement of goods can be done automatically, which reduces the process of moving goods manually.
Affordable and stable
Compared to shelves that use electric power to move goods, gravity flow rack's components are mostly mechanical, with very few electronic components, so the probability of failure is very low. In terms of price, gravity flow racks with mechanical components are also cheaper.
Reduced labor costs
The gravity flow rack system simplifies the work in the warehouse, as the staff only needs to deposit and remove the goods, so the same amount of goods in a warehouse with a gravity flow rack system requires less labor to complete the work.
Disadvantages of gravity flow racks
High initial cost
Gravity flow racks are more expensive than traditional static racks, and if customization is required, the price will increase.
High maintenance costs
Although most of the components of a gravity flow rack are mechanical, the roller system and the track system require maintenance as they are subject to wear and tear during the daily operation of the rack and need to be serviced and maintained on a regular basis.
Limitations on the type of goods
Since the aisle of the gravity flow rack is a fixed size space, the goods are not allowed to have irregular shape, unstable packing or too light/heavy goods. This is because if the goods are involved in the above situations, then the goods may not move well or may slip/jam.
Not suitable for low turnover goods
Since gravity flow rack adopts FIFO inventory management mode, it is more suitable for high turnover goods, and long-term fixed storage of goods may lead to accelerated aging of the sliding system and other situations. So if you need to store low turnover goods, it is better to use static racking like pallet racking.
Complicated installation
The design of the gravity flow rack itself makes the installation process relatively complicated, and if it is in some irregular spaces or special warehouses, the design and installation will be more difficult. And most gravity flow racks are difficult to adjust the layout of the rack after installation.
Application of gravity flow rack
Food/Beverage Industry
Let's start by understanding the storage characteristics and needs of the food or beverage industry. Three very similar characteristics of stored goods in these two industries are that they have strict product shelf life, large quantities of the same type of goods, and fast turnaround times.
With such storage needs, the advantages of gravity flow racks can be maximized in these industries.
Pharmaceutical and Medical
Pharmaceutical and medical goods are similar to those in the food and beverage industry, in that both have strict product shelf lives. It is important to ensure that goods can be taken out sequentially according to the date of manufacture, and the FIFO inventory management approach of gravity flow racks can be very helpful.
Manufacturing Warehouse
In a manufacturer's warehouse, the goods produced in batches are of the same type and in large quantities. Manufacturers also need to move goods out of the warehouse frequently, so gravity flow racks are a good choice for them.
E-Commerce/Retail
Warehouses in both industries have a need to increase picking speeds, as high frequency orders have to be picked faster. As I mentioned the carton flow rack, this type of rack was created for this use.
Conclusion
When we finish understanding gravity flow racks, we know whether we are really suitable to choose it for our storage needs.
And in the end, we would like to introduce you to us. We are a racks manufacturer from China, HEDA is our brand. If you are looking for a reliable supplier, I think maybe you can contact us to get your own free quote service!