How do we keep assembly picking separate from deliveries?

In an Aurora flex building along SR-43, the drawing reserves a replenishment route behind the lanes and a collection path at the front. Delivery staging should not occupy either route. Those boundaries are established before final lane quantities are quoted.

Should every component get a flow position?

No; repeated picks and predictable carton sizes are the stronger candidates. Low-frequency parts may remain in bins or shelving alongside the face. Review the order history so the lane allocation follows the assembly workload rather than merely the inventory list.

What happens when a supplier changes its packaging?

Measure the revised carton before moving dividers. A change in base stiffness, weight or width can affect travel as well as fit. Some updates need different rollers or lane hardware; an adjustment alone is not guaranteed to solve every packaging change.

Can reserve pallets stay above the new lanes?

They can be considered after the supporting rack and access are reviewed. For an SR-82 building, we also check replenishment handling and the usable pick height. The revised arrangement must account for both reserve storage and the newly introduced hand-pick activity.

Carton Flow Rack system inside a Ohio warehouse

Aurora, Ohio

Carton Flow Rack in Aurora, OH

Name: Cleveland Pallet Rack
Address: 11811 Shaker Blvd., Cleveland, OH, 44120, US
Telephone: (216) 434-6607
Price range: $$

Carton flow rack in Aurora replaces the static shelf positions that slow down case picking. Cases and totes travel inclined roller lanes from the loading aisle to the pick face, presenting the oldest carton first in the lane sequence. Light manufacturing and industrial distribution operations along SR-43 and SR-82 often pick assembly cartons or order lines all day, and presentation is what speeds that work up.

Because restocking works the rear aisle while pickers work the front, carton flow racking removes the daily collision between replenishment and order selection. Lane assemblies typically mount into the lower levels of pallet rack bays, so reserve stock stays overhead.

(216) 434-6607

Carton Flow Racking: Lanes, Pitch and Picking

Gravity moves the cases; the design sets how well they move. Four decisions shape every installation.

Carton movement

Assembly supplies enter inclined roller tracks from behind the pick face. Selecting the pitch requires the smallest loaded carton as well as the largest, because mixed packaging does not behave identically.

Two working aisles

Front removal and rear replenishment support FIFO while separating tasks. The layout must actually provide access to both sides; a flow section against a wall loses that operating advantage.

Flexible product slots

Adjustable dividers allocate width to each assembly carton or tote. A revised SKU mix may require different slot sizes, so we check the adjustment range before selecting track sections.

Existing bay connections

Retrofitting means verifying the supporting pallet rack rather than assuming every attachment fits. Beam dimensions, connectors, loading and available depth determine the suitable flow assemblies for those bays.

Carton Flow Rack Design and Installation in Aurora

We begin with your SKU list, carton dimensions and weights, and daily line counts. Those facts decide which items earn lanes, how wide each lane runs and how deep the lanes go.

The CAD layout shows lane counts, pick-face heights and the replenishment aisle against your building's measured columns and doors. A pick module with conveyor is sketched as an option where volume justifies it.

Installation is handled by experienced crews we schedule and manage. Lanes are assembled, the structure is anchored to the floor, dividers are set to your cartons, and handover includes a slotting map.

For Aurora, carton flow racking decisions start with the full picking sequence. Order-picking speed is not a percentage we promise from a photograph. We first look at walking distance, search time, refill interruptions and where completed orders are collected. A compact face may reduce travel, but giving too little width to active SKUs can create waiting elsewhere. Pick modules merit the same scrutiny: extra levels bring additional replenishment and transfer tasks, not simply more slots.

Related storage pages for your Aurora operation:

Aurora warehouse storage Carton flow system overview Aurora pallet flow lanes Pushback options in Aurora

Assembly carton picking

Distribution order lines

Case picking under pallet reserve

Operations separating pick and restock

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Where Carton Flow Rack Fits Aurora Picking

The gain is measured in footsteps. A picker facing a well-slotted flow lane picks the next line without walking or searching, and the lane refills itself by gravity. We size lanes and dividers from your measured cartons so the face stays organized as the mix shifts.

This site operates as a division of Warehouse Equipment & Supplies Co., a rack supplier and installer since 1997. Proposals itemize lanes, dividers, frames and accessories as new material, drawn from your carton dimensions and pick volumes.

Free warehouse consultation

CAD layout with position counts

Installation by experienced crews we schedule and manage

Carton flow rack with gravity wheel beds and case lanes

Carton flow shelving in use on a warehouse pick line

Aurora Buildings and Layout

The SR-43 and SR-82 corridors mix newer flex space with older light-manufacturing floors. Newer buildings give room for dedicated replenishment aisles behind the pick face; older ones need column and aisle measurements before lane counts are fixed. Door positions decide where the loading aisle can run without crossing outbound staging.

light manufacturing

industrial distribution

Recent Installations

Racking projects completed for warehouses across Greater Cleveland and Northeast Ohio.

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Get a Carton Flow Rack Quote for Your Aurora Warehouse

Send your Aurora assembly list with carton measurements, order-line frequency and photos of the supporting bays. The consultation will turn those inputs into a picking plan and an itemized quotation.