Does your team walk more than they pick up orders? Are order queues jammed? Are defects appearing where there is excessive handling? flow rack system It is designed to break this cycle. It delivers continuous gravity flow, respects FIFO (First In, First Out), reduces movement, and gets the right item to the operator's hand.
In high-volume operations, storage alone is not enough; flow must be guaranteed. When properly sized, the flow rack It reduces movement, prevents damage from excessive handling, and provides predictability in order preparation.
In this content, you'll understand why Flow Rack improves performance, how it works in daily use, and which variables deliver better results for your operation.
How does the flow rack system work?
The flow rack uses inclined rails or rollers. Gravity does the work of moving the products from the entry point to the removal point. As soon as an item is removed, the next one automatically slides forward.
This continuous movement reduces the need for handling and speeds up picking. The result is a faster, more ergonomic, and safer process for operators and goods.
This system follows the principle FIFO, ideal for high-turnover inventory and products with a defined expiration date.
What does the FIFO method mean?
FIFO is the abbreviation for First In, First Out. In practice, this means that the first item stored will be the first to be removed.
This method is essential for perishable products, frozen goods, and medications, as it ensures that expiration dates are respected. By following this logic, the flow rack maintains product integrity and prevents losses due to expiration.
What are the advantages of a flow rack?
Flow racks offer benefits that directly impact warehouse productivity and safety:
- Integration with automation, such as Pick-by-light systems.
- Space optimization with separate loading and unloading areas.
- Reducing picking time and increased productivity.
- Enhanced ergonomics for operators, reducing unnecessary effort.
- Fewer breakdowns by minimizing direct handling of the products.
How do you size a flow rack to maintain FIFO and increase speed?
- Map the ABC curve, hourly volumes, and peaks.
- Define depth per SKU, considering replenishment and the risk of stockouts.
- Adjust the tilt to overcome friction without accelerating too much.
- Standardize packaging for stable sliding.
- Design for usable width and guides to prevent lateral friction.
- Position the first setting within the operator's reach.
In Success stories from Bertolini Storage Systems, It is common to observe significant savings in operator travel, which impacts productivity and cost per order.
In which operations is a flow rack suitable?
The system is recommended for:
- Medium and high turnover inventories
- Products with controlled expiration dates
- Distribution centers that require high precision in picking.
- Order picking lines with high daily volume.
Its versatility allows for integration with others. storage and automation systems, ensuring flexibility and scalability.
In which scenarios does a flow rack generate the highest return?
- Medium and high turnover inventories, with orders placed in installments.
- Products with expiration dates and batch control.
- Separation lines with strict SLAs and seasonal peaks.
- Operations that need to reduce overlaps between supply and collection.
Advantages of the Bertolini Flow Rack
In addition to following the FIFO philosophy, the Bertolini Flow Rack delivers benefits that directly impact warehouse performance:
- Space optimization – It separates loading and unloading areas, preventing the crossing of flows.
- Reduction in picking time Less travel, greater productivity.
- Ergonomics – Positioning items at the ideal height to reduce physical effort.
- Fewer breakdowns Less direct handling and controlled flow prevent damage.
- Integration with automation – compatible with systems Pick-by-light and other logistics equipment.
FAQ – Frequently Asked Questions about Flow Racks
What is the Flow system?
The Flow system is a dynamic storage solution that uses inclined rails or rollers to move products by gravity, facilitating replenishment and order picking.
What is Flow Rack?
Flow Rack is a type of dynamic shelving that organizes products in a continuous flow, using the FIFO (First In, First Out) method, reducing movement and speeding up picking, ideal for high-turnover inventories.
Does a flow rack require electricity?
No, the movement is by gravity. Automation is optional.
Does it work with plastic and cardboard boxes?
Yes, provided the track, slope, and guide rails are properly sized for the material and weight.
Is the Flow Rack system always FIFO?
In the correct configuration, yes. The design and replacement process preserve the order of output.
Is it possible to scale Flow Rack without interrupting operations?
Yes, the structure is modular. The planning defines expansion windows with minimal impact.
More than just storage, intelligence and efficiency in handling.
THE flow rack It organizes the rotation by gravity, shortens operator travel distances, and protects the product with fewer touches.
With proper sizing and integration with WMS and automation, the operation gains speed, predictability, and control, without increasing the team's effort.
Do you want to apply? FIFO and LIFO safely, and understand where each method works best in practice, in storage systems. Download our free infographic about the FIFO and LIFO principles. and delve deeper with clear examples and faster decisions.
And if you'd like to speak with our team of experts to get more details on how to optimize your logistics operation. Schedule a diagnosis now..
