Streamlining Super Sack Storage - The Power of Pallet Flow Rack | Mallard Manufacturing

When it comes to super high-density storage for super sacks, there's no better choice than pallet flow rack! In the bustling world of mining and production, efficiency isn’t just a goal-it’s a necessity. Imagine a scenario where raw materials essential for everyday products are handled with ease and precision, ensuring smooth operations and timely production. Now, imagine the perfect high-density storage solution to hold those materials in an organized, safe, easy-to-access, and space-saving unit… ok, stop imagining and take a good look at pallet flow rack!
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Why Pallet Flow Rack?
For a mining and production company dealing with vast quantities of raw materials stored in oversized super sacks, traditional storage methods -particularly floor stacking, can quickly become a bottleneck and a safety concern. Pallet flow rack offers a transformative solution by securing the sacks in a consolidated footprint with deep storage lanes and multiple vertical levels that maximize storage density. SKUs are organized by lane to streamline storage and extraction activities and ensure accuracy.
The size of super sack loads may pose a challenge to other storage systems, but not for pallet flow rack. Pallet flow lanes are configured uniquely to your inventory specs - we create a stable lane with wheeled or roller rails and add speed controllers and other accessories as needed to ensure good, reliable, consistent flow. Our in-house testing lab ensures that your system will perform as expected. Take a look at how these customer-supplied super sacks performed in the lab.
The Mallard Test: Super Results
The Mallard team put their flow lane design to the ultimate test with our super sacks. The verdict? Dare we say it… super! The super sacks flowed at a very controlled speed and tracked evenly for the length of the lane -translating to reduced handling times, minimized product damage, and enhanced safety in the workplace.
Pallet Flow Lane Design:
--Wheeled pallet flow: 3 rails on 3”/2”/3” centers, respectively
--Load weight: 2212 lbs.
--Pitch: 7/16” per foot
--Speed controllers: Drop-in spaced at 52 apart
--Pallets: 44” w x 44” l x 46” high
--Lane width: 43” out to out
We encountered some restart issues with pallets in poor condition, which were easily restarted with the Plugging Method, i.e., the forklift operator pushes back slightly to gently bump the pallet before extracting the front pallet. Usually, that is all that is needed to restart flow; however, we strongly caution against loading broken or compromised pallets in the lane, as they can get stuck and require remediation.
Pallet Flow Rack Benefits for Super Sack Storage
*Space Optimization: Maximize vertical and horizontal space
*Efficient Handling: Super sacks glide from the load side down to the extraction side, reducing forklift travel time and optimizing workflow.
*Inventory Control: Easy FIFO (First-In/First-Out) inventory rotation ensures that older stock is used first, minimizing waste and maximizing freshness of materials.
*Customizable Solutions: Mallard’s expertise lies in tailoring pallet flow rack systems to fit the unique needs of every client, ensuring maximum ROI and operational efficiency.
Our gravity flow rack specialists have a proven track record of reliable, innovative solutions to help customers streamline operations, boost productivity, and stay ahead of the competition.
Contact Mallard today to discover how gravity flow solutions can help maximize your warehouse space and productivity.