Carton Flow Rack Suppliers in Illinois — 4 Companies
Carton flow is pallet flow's smaller sibling — gravity-fed roller or wheel tracks built into rack shelves so cases and cartons roll forward as you pick from the front. It turns a static pick face into a self-replenishing one, cutting walk time and keeping the most-picked items within arm's reach. Chicago is the undisputed freight capital of North America. More rail freight passes through Chicago than any other city on the continent. The I-55, I-80, and I-88 corridors south and west of the city contain one of the densest concentrations of warehouses and distribution centers in the world.
Learn more about carton flow rack in Illinois ↓Carton Flow Rack Suppliers in Illinois (4)
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Rack Builders Inc.
Rack Builders designs and manufactures structural storage rack systems built to RMI specifications by licensed structural engineers. They specialize in selective push-back pallet flow and carton flow systems.
Mallard Manufacturing Corporation
Mallard Manufacturing is a premier gravity flow rack systems manufacturer operating two state-of-the-art facilities. They specialize in pallet flow carton flow push-back rack and gravity conveyor systems with nationwide sales and support.
Frazier Industrial Company
Frazier Industrial is the largest producer of 100% structural steel pallet rack systems in North America. With 10 fabrication facilities they serve industries including manufacturing automotive cold storage and e-commerce.
When to Choose Carton Flow Rack
- ✓Each-pick or case-pick operations with high SKU counts
- ✓Order pickers spend too much time walking between picks
- ✓You need a self-replenishing pick face that stays organized
- ✓FIFO rotation at the carton level is required
- ✓You're designing a pick module or mezzanine pick area
Key Specs to Ask About
- •Track type (wheel rails, full-width rollers, or tilted shelf inserts)
- •Lane width (sized to your carton/case dimensions)
- •Number of lanes per shelf level
- •Shelf depth (typically 3-6 cartons deep per lane)
- •Knuckled tracks or flat — knuckled helps with heavier cartons
- •Integration with pick-to-light or voice-pick systems
How It Compares
| Factor | Carton Flow | Static Shelving |
|---|---|---|
| Replenishment | Self-replenishing — gravity feeds product forward | Manual — must restock shelf positions |
| Pick speed | 250-400+ picks/hour achievable | 80-120 picks/hour typical |
| Best for | High-volume each-pick and case-pick | Low-velocity items, parts rooms |
| Cost | $$$ (flow tracks add to rack cost) | $ (basic steel shelving) |
| Space efficiency | Moderate — lanes are sized to carton dimensions | High flexibility — any item on any shelf |
Carton flow makes sense when pick speed is the priority — the gravity-fed lanes keep product at the pick face without manual restocking. Static shelving works for lower-velocity items where the simpler system is adequate. Most pick operations use both — carton flow for fast movers, shelving for slow movers.
Every day, approximately 500 freight trains pass through the Chicago metro area. That's more than any other city in the world. The rail yards around Joliet and Elwood are why there's a warehouse every quarter mile along I-55.
Frequently Asked Questions
What's the difference between carton flow and pallet flow?
How much does carton flow rack cost?
Can I retrofit carton flow into my existing rack?
How many carton flow rack suppliers are in Illinois?
Before carton flow existed, order pickers in the 1960s walked an average of 12 miles per shift. That's nearly a half marathon, five days a week, in steel-toed boots.
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