What is carton flow rack actually used for?

Case and piece picking. Cartons ride gravity wheel beds so the next unit advances to the pick face automatically, cutting walking time and keeping the line organized as SKU counts climb.

How is it different from static shelving?

On static shelving, a picker reaches into the bay and someone has to physically face the product afterward. Carton flow feeds from behind and presents at the front, so rotation is automatic and the pick position never moves.

Will soft or lightweight cartons travel through the lanes?

Full-width wheel beds handle mixed and flimsy cartons far better than spaced roller tracks. If your cases vary in stiffness, that's the specification we'll recommend, and we test travel with your actual cartons at installation.

Carton Flow Rack warehouse storage system

Paterson, New Jersey

Carton Flow Rack in Paterson, NJ

Name: Newark Pallet Rack — Paterson
Address: 146-B Ferry St., Newark, NJ, 07105, US
Telephone: (973) 318-1590
Price range: $$

A Paterson apparel or light-assembly operation can spend too much time searching static shelves for cases when many item sizes feed the same daily workstations.

Carton Flow Rack planning starts with that Paterson constraint, not a drawing borrowed from another building. Place frequently picked cartons within practical reach and fit replenishment behind the face without blocking mill-building circulation. We compare capacity, access, and the way your inventory moves before recommending a configuration. Send your building dimensions and load details for a free warehouse consultation. You receive a layout and itemized pricing before deciding what to order or move.

(973) 318-1590

Why Paterson Warehouses Work With Us

Place frequently picked cartons within practical reach and fit replenishment behind the face without blocking mill-building circulation. Around the Passaic River mill district along Route 20, the practical question is how storage will work alongside receiving, dispatch, and the space reserved for people and production. Paterson operations dealing with textiles and apparel need a plan that reflects their actual product mix rather than a generic rack count. We ask about the peak week as well as normal inventory so the drawing does not depend on an unusually quiet day.

For carton flow rack, the useful comparison is what changes at the working face: gravity wheel beds feeding cases to a fixed pick face. A building in the Great Falls district may have a different column grid, usable height, or loading approach from the next address. Those measurements belong in the scope before materials are priced.

Newark Pallet Rack is a division of Warehouse Equipment & Supplies Co.. You have a single contact for layout revisions, the itemized scope, delivery planning, and installation coordination with installation partners. We explain the tradeoffs, identify information still needed, and keep the Paterson drawing available for later expansion or replacement components. The aim is a storage plan your team can use, with clear responsibilities rather than assumptions.

Free warehouse consultation

CAD layout with position counts

Installation by trusted installation partners

Carton flow rack with gravity wheel beds and case lanes

Carton flow shelving in use on a warehouse pick line

Operations We Rack Around Here

Nearby areas we work in regularly include the Passaic River mill district along Route 20, the Great Falls district, Bunker Hill, Riverside, Madison Avenue industrial.

Textiles and apparel

Food processing

Light manufacturing

Wholesale distribution

How Carton Flow Rack Works

Cases advance to the picker instead of the picker hunting for cases.

Inclined wheel beds

A full-width wheel bed or roller track sits on a slight incline inside a standard bay, so cases move forward under their own weight without power.

Pick from a fixed position

The picker always reaches for the same forward spot in the lane. Travel time drops, and so does the time spent searching for the next case.

Restock from behind

Replenishment loads the high end of the lane from a separate aisle, so restocking never blocks or slows the pick line, and rotation stays first in, first out automatically.

One lane per SKU

Lane dividers set the width for each case size, giving every SKU its own face - a width that can be resized as your product mix shifts.

What Your Carton Flow Rack Project Includes

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.

Place frequently picked cartons within practical reach and fit replenishment behind the face without blocking mill-building circulation. For the Paterson site near the Passaic River mill district along Route 20, we confirm receiving access and where components can be staged before agreeing on delivery windows. The finished drawing identifies the storage zones, access requirements, and capacities for the proposed arrangement. Product-specific components and testing are included in the scope rather than assumed to be interchangeable with ordinary pallet rack. You receive a written quote and a schedule based on the approved scope and confirmed availability, not an unqualified completion promise.

Case and each picking operations

Order fulfillment lines carrying many active SKUs

Grocery, beverage, and consumer goods distribution

Kitting and light assembly feed lines

Bays that need reserve pallets stacked above the pick face

Call (973) 318-1590

Recent Installations

Racking projects completed for warehouses across Greater Newark and North Jersey.

View More Projects

Get a Carton Flow Rack Quote for Your Paterson Warehouse

Send the basics and we will follow up with a layout and pricing. Prefer to talk it through? Call (973) 318-1590.

Newark Pallet Rack

146-B Ferry St.

Unit #1214

Newark, NJ 07105

(973) 318-1590

Monday - Friday: 8:00 AM - 6:00 PM

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