Gravity flow lanes for Gaylord boxes, large returnable containers, bulk bins, and oversized totes on pallets — delivering FIFO lot rotation and high-density container storage with forklift or pallet jack pick-face access. Manufactured in Auburn Hills, MI.
Lane widths and roller pitch are designed for the specific Gaylord or bulk bin pallet footprint — with guide rails matching the pallet or container base dimensions for consistent lane travel without sidewall contact.
Returnable large container guide rails are designed to the container corner post locations, preventing tipping or shifting during gravity travel while allowing smooth forward motion in the lane.
Adjacent full-container and empty-container return lanes can be designed in the same rack structure — reducing empty container handling time and keeping the workstation floor clear.
Lane pick-face heights are designed for either forklift or pallet jack access based on the operation requirement — eliminating over-specification of equipment for lanes that only need pallet jack pick.
Container presence sensors at the pick face provide lane-empty signals to WMS or ERP systems, triggering replenishment work orders before the production line runs out of material.
Large container flow lanes achieve 30–50% higher storage density than equivalent selective racking for large containers by eliminating dedicated pick aisles between rows.
Custom to pallet or container footprint; typical 44–56 in. for Gaylord lanes; wider for RLC containers
Up to 4,000 lbs per container position; rated per full container gross weight with 2:1 safety factor
60–90mm steel tube per load; minimum 3-roller contact at all pallet positions throughout lane depth
2-deep to 6-deep; depth set per consumption rate and replenishment frequency requirement
3–4% standard; speed controllers per lane; calibrated per container gross weight
Optional adjacent return lane in same rack bay for empty container gravity return to load end
Entry funnel guides and exit positive stops; RLC corner post guides for returnable container lanes
Hot-rolled steel; powder coat finish standard; galvanized available for outdoor or wash-down use
Photoelectric or weight-based presence sensor at pick face; output to WMS, MES, or andon system
Gaylord box lanes for loose stamped, molded, or machined parts in FIFO lot rotation storage.
Bulk bin flow lanes for fast-moving SKUs in high-volume order fulfillment operations.
Large RLC gravity flow lanes delivering bulk components to production line kitting and feeder stations.
Produce bulk bin gravity flow staging in cold storage and ambient distribution for FIFO rotation.
Gaylord box lanes for molded part storage and FIFO sequencing to secondary assembly operations.
Large container gravity flow staging for returned goods, recyclable materials, and scrap accumulation.
Bulk hardware, fastener, and small-part Gaylord lanes in hardware distribution center pick operations.
Bulk resin, pellet, and powder Gaylord gravity staging for plastics processing and compounding lines.
A Gaylord box (bulk bin) is a large corrugated or plastic container, typically 40x48 inches on a pallet, used to store loose parts, components, or bulk material in bulk quantities. In a flow rack lane, the Gaylord on its pallet gravity-feeds from the load end to the pick face. The lane width accommodates the pallet footprint, and the roller pitch supports the pallet base across the full lane depth.
Yes. Returnable large containers (RLCs) — molded plastic or steel mesh bulk containers on pallet bases — are commonly used in flow rack lanes. The flow lane design is matched to the RLC base dimensions. RLC guide rails are designed for the specific container corner post locations to prevent the container from shifting or tipping during gravity travel in the lane.
Large container pick faces are typically accessed by forklift or pallet jack depending on floor-level clearance. Forklift-access pick faces require 48+ inch clear beam height above the pick face pallet to allow fork entry. Pallet jack access requires a floor-level lane with no beam obstruction at the pick face end. The access method is confirmed in the design phase based on available equipment.
A loaded Gaylord box on a pallet typically weighs 1,000–2,500 lbs depending on content density. Steel mesh RLCs with metal parts can reach 3,000–4,000 lbs. Lane ratings are calculated per the specific container and content gross weight, with a 2:1 safety factor applied. High-density metal part containers require 75–90mm rollers and heavier rail gauge.
Yes. A common configuration pairs a full-container flow lane with an adjacent empty-container return lane. Empty containers are pushed onto the return lane at the pick face and gravity-feed back toward the supply end for forklift pickup and refill. The paired lane configuration minimizes empty container handling time and keeps the work zone clear of empty containers.
Share your container type, pallet footprint, content weight, lane count, and pick-face access method — our engineers will design a system optimized for your operation.
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