Carton Flow Rack Systems in Kansas City

Kansas City warehouses near the I-35, I-70, and I-435 freight corridors need storage that matches the way orders leave the building. Carton flow rack is built for the picker, not the pallet. Cases sit on inclined wheel beds, so every time a picker takes one, the next slides forward to the exact same spot - no reaching, no re-facing product, no walking to find the case that should be there. Restocking happens from a separate back aisle, so replenishment never interrupts the pick line. Before adding another row, compare what remains accessible, how inventory rotates, and where incoming freight waits. A free warehouse needs analysis starts with your floor plan and storage profile so the next investment solves the handling problem rather than just filling another corner with steel.

It's the right system when picking is by the case or the each, not the pallet, and when enough SKUs need a dedicated face that static shelving turns into a maintenance problem. Most warehouses run it in the lower levels of a bay with reserve pallets stacked above, so one footprint handles both active picking and overflow storage.

We size wheel beds and lane widths to your case dimensions, pick rate, and SKU count, and show where the fastest movers should sit in the bay.

The West Bottoms, Executive Park, and Northland represent different warehouse settings within the same freight market. An older building's column grid should not be treated like the open floor of a newer distribution facility. Receiving from I-70 and I-435 also needs staging space that is not counted as permanent storage. We keep those constraints separate when comparing a bulk reserve block with working pick aisles.

We use carton dimensions and picks per shift to assign lanes rather than divide every shelf equally. A soft carton needs different support from a stiff case, and a fast-moving item may need more than one lane. The replenishment path belongs on the same drawing as the pick face, with reserve pallets treated separately from case-level flow. The local plan also accounts for access along the I-435, I-70, and I-35 freight corridors, delivery space, and the difference between a receiving window and a storage window. We ask your team to confirm those constraints from the building information and daily schedule.

As a division of Warehouse Equipment & Supplies Co., we put the layout, material list, and installation scope in front of you together. You get a free design consultation, an itemized quote, and installation teams we manage, with one contact for revisions, scheduling, and replacement parts. We explain the tradeoffs before the purchase and keep the approved configuration available for later changes.

The project starts with the case list: dimensions, weight, whether the carton bottom is stiff or soft, and picks per SKU per day. Those numbers decide wheel bed style, lane width, and how much face each SKU is worth giving up.

From there we lay out the bay - how many flow levels, at what incline, and what sits above them. In most designs, the fastest movers get the golden zone at waist height, slower SKUs move to the upper or lower levels, and reserve pallets stack overhead in the same footprint.

The quote itemizes frames, beams, wheel bed or track, lane dividers, front stops, and shelf-level accessories, with the layout showing lane assignments by SKU. Installation sets the incline, tests case travel with your actual cartons, and adjusts before the line goes live.

The payoff is a pick line where cases present themselves, restocking stays out of the way, and lane widths can be reset whenever SKUs come and go.

Before delivery is committed, we review the receiving window, unloading responsibilities, and available staging area with your team. The approved layout and component list are used to agree the installation sequence; a phased approach is assessed against your shipping schedule rather than promised automatically. Any changes to pallet weights, handling equipment, or inventory mix are reviewed before loading the completed system. Keep the configuration and capacity information with the operating team so later beam moves or added levels are checked against the rated arrangement.

Recent Installations

A sample of racking projects completed across the region.

Carton Flow Rack Questions We Hear Most

Where We Work

Located in Kansas City, we serve the entire KC metro area with industrial pallet racks and warehouse storage solutions.