High-density bin flow storage systems use multi-tier aluminum T-slot frames to stack gravity-fed bin lanes from floor to ceiling, achieving 80–120 SKU positions per linear metre of bay in high-SKU small-parts environments. Tier heights and lane widths are engineered around the specific bin mix to maximise density without ergonomic compromise.
Frames engineered to 2400mm height supporting 6 independent tiers — full building height utilisation for maximum SKU density per square foot.
Top tier at eye level, bottom tier at waist height — all bins in the primary and secondary reach zones, eliminating ladder access or floor-level bending.
Tier spacing sized precisely to bin height plus clearance — no wasted vertical space between tiers for maximum storage density.
Different tier heights within the same frame accommodate tall bins on wide tiers and shallow bins on narrow tiers — no uniform tier height waste.
High-velocity SKUs assigned to eye-level middle tiers — lowest effort pick height for most-consumed parts.
Standard 1200mm wide bay yields 8–24 lanes per tier, 48–144 total lane positions per bay — the highest gravity-fed small-parts density available.
Dense bin flow walls for high-SKU parts stores — gravity-fed FIFO with visual management across hundreds of SKU positions per aisle.
Full-height supermarket kanban walls supplying multiple assembly lines — maximum SKU positions per aisle metre for high-mix facilities.
High-density each-pick bin flow walls for e-commerce and B2B distribution — maximum pick-face positions per warehouse footprint.
Controlled small-parts stores with full FIFO traceability across hundreds of controlled part numbers in a single secure crib.
FIFO-compliant bin lanes for pharmaceutical packaging components — lot traceability enforced by gravity-fed FIFO rotation.
High-density ESD-safe (optional) bin flow walls for electronics component stores serving multiple assembly cells.
High-density bin flow replaces open shelving in MRO cribs — FIFO rotation, visual management, and higher SKU density in the same footprint.
Dense bin flow walls for cutting tools, inserts, and consumables — FIFO ensures oldest stock consumed first, reducing tool life waste from age.
A standard 1200mm wide bay with 6 tiers can achieve 48–144 lane positions depending on lane width. Narrow 50mm lanes at 6 tiers yield up to 144 positions. Wide 100mm lanes at 6 tiers yield 72 positions. Actual counts depend on your bin mix.
Modular Solutions designs all bins to fall within the primary reach zone (waist to shoulder) and secondary reach zone (shoulder to eye level) — typically 300mm to 1800mm from floor. Bins above 1800mm are not recommended for frequent access. Anti-fatigue matting and step stools are used only for infrequent access above standard reach zones.
Frames above 1500mm include rear bracing and floor anchor kits. Anti-tip standards require frames to be anchored when height-to-depth ratio exceeds 3:1. Modular Solutions specifies anchoring requirements in the installation drawings.
Yes. Different tier heights are achieved by setting shelf bracket positions at different T-slot intervals. Modular Solutions optimises tier height per tier based on the bin height for that tier — no unused vertical space between tiers.
Standard frames reach 2400mm. Custom frames up to 3000mm are available with additional intermediate bracing and engineering review. Heights above 2000mm require floor anchoring and a structural sign-off.
Frames disassemble into uprights, horizontal beams, and brackets using standard T-slot tools. Modular Solutions disassembly and relocation service is available, or in-house maintenance teams can relocate frames with the assembly manual and standard hex keys.
Request a quote or contact our engineering team to discuss your high-density bin flow storage requirements.