--- title: "Carton Flow Rack in Charlotte, NC | Rack Systems" url: https://charlottepalletrack.com/products/carton-flow-rack description: "Carton Flow Rack in Charlotte, NC. Free CAD layout and itemized quote. Compare storage access and capacity for your warehouse." lang: en --- Image: Carton Flow Rack system in an industrial warehouse (https://charlottepalletrack.com/__l5e/assets-v1/d8101084-1d24-42fc-bc5a-eb546281ef83/carton-flow-hero.jpg) # Carton Flow Rack Systems in Charlotte, NC Charlotte case pickers can lose a shift walking between scattered cartons while reserve pallets occupy the best picking space. Compare active case lanes with replenishment demand for a Northlake fulfillment operation. Charlotte freight routes meet at I-85 and I-77, while Steele Creek connects warehouse operations with the airport and intermodal corridor. A storage plan here has to separate reserve inventory from dock staging instead of treating all empty floor as rack space. Carton flow shelving brings the next case forward on inclined rollers or wheel beds so the picker works from a defined face. Replenishment normally enters from behind, making the back-loading route part of the design rather than an afterthought. We review carton dimensions, bottom stiffness, weight, SKU demand, and reach heights. Your free layout shows lane assignments and reserve-storage options, with an itemized quote and case-travel requirements for the selected system. (704) 480-3833 ## Why Charlotte Warehouses Work With Us We plan Charlotte projects around the actual building and inventory, not a broad claim about every warehouse in the metro. A Westinghouse Boulevard receiving area and a Northlake order-picking operation can need different lane depths, replenishment routes, and work windows. The first drawing makes those differences visible. For carton flow rack specifically, the local design decision is straightforward: compare active case lanes with replenishment demand for a Northlake fulfillment operation. We review this against the actual Steele Creek building and its working-stock requirements before the quote is approved. Carton flow is specified from cases and picking behavior, not from pallet weights. A light or soft-bottomed carton may need a different support arrangement from a stiff heavy case. We ask which SKUs run out between refills, how often replenishment can occur, and which levels people can reach comfortably. That information sets lane width and count rather than dividing every bay evenly. Reserve pallets above a pick zone are considered only with a suitable rack configuration and capacity review. The scope lists flow tracks or beds, dividers, stops, supports, and any rack changes. Representative cases are checked for travel so a full lane does not become an inaccessible row of stuck cartons. ## How Carton Flow Rack Works 1 ### 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. 2 ### 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. 3 ### 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. 4 ### 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. Image: Carton flow rack with gravity wheel beds and case lanes (https://charlottepalletrack.com/__l5e/assets-v1/40907050-7b75-417f-b4a6-6ac621d62446/carton-flow-rack.jpg) Image: Carton flow shelving in use on a warehouse pick line (https://charlottepalletrack.com/__l5e/assets-v1/d8101084-1d24-42fc-bc5a-eb546281ef83/carton-flow-hero.jpg) ## Where It Fits Best 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 ## What We Need to Design It - What are your case dimensions and weights? - How many SKUs need a dedicated pick face? - How many picks per SKU on a busy day? - Is there a separate aisle available for restocking? - Are reserve pallets going above the pick levels? ## What a Project Includes For Charlotte, start with the floor plan and the operating constraint: compare active case lanes with replenishment demand for a Northlake fulfillment operation. The scope is reviewed against your Steele Creek site, not a catalog example. 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 work is released, the final scope confirms the approved layout, capacities, accessories, installation responsibilities, and access requirements. Our team handles the permit side for you. Changes in load, pallet construction, or handling equipment should be raised before ordering so the drawing and quote describe the system your team will actually use. 1 Phone consultation 2 CAD layout 3 Itemized quote 4 Delivery & installation ## Recent Installations A sample of racking projects completed across the region. Image: Pallet rack installation (https://charlottepalletrack.com/__l5e/assets-v1/9e6d591a-1b42-4328-8d0c-3ff129072082/project-orange-blue-rack.jpg) Image: Pallet rack installation (https://charlottepalletrack.com/__l5e/assets-v1/e271d582-2fce-4cff-97da-462ddab27097/project-blue-tall-rack.jpg) Image: Pallet rack installation (https://charlottepalletrack.com/__l5e/assets-v1/ec5ca081-4183-457a-914c-fb74a5815fa2/project-dc-aisle.jpg) Image: Pallet rack installation (https://charlottepalletrack.com/__l5e/assets-v1/9bee7a3e-6b3b-4d2b-8863-c37f0e1dd966/project-distribution-center.jpg) Image: Pallet rack installation (https://charlottepalletrack.com/__l5e/assets-v1/880d5178-c293-49a2-82ae-3365f0c1628c/project-drive-in.jpg) Image: Pallet rack installation (https://charlottepalletrack.com/__l5e/assets-v1/91e4b43a-9eb0-4105-9d30-657028a00c91/project-loaded-aisle.jpg) Image: Pallet rack installation (https://charlottepalletrack.com/__l5e/assets-v1/e1312ce4-7800-4267-82fd-dd273b917f2a/project-igt-install.jpg) Image: Pallet rack installation (https://charlottepalletrack.com/__l5e/assets-v1/259a43d6-5be8-4f8e-920d-5c0dcdcf44a4/project-wire-deck.jpg) Image: Pallet rack installation (https://charlottepalletrack.com/__l5e/assets-v1/aa0a820f-d334-4983-9a3f-a2435e8bb4aa/project-shelving-bays.jpg) Image: Pallet rack installation (https://charlottepalletrack.com/__l5e/assets-v1/b572c5bc-8d66-4163-afa0-d13a2eb10eef/project-green-orange-rack.jpg) View More Projects: https://charlottepalletrack.com/projects ## Get a Carton Flow Rack Quote Send the basics and we will come back with a layout and pricing. Prefer to talk? Call (704) 480-3833. ### What's Included: - Free warehouse consultation - CAD layout drawings - Itemized project quote - Rack type recommendations - Installation timeline ## Carton Flow Rack Questions We Hear Most ### What type of pallet rack do I need? ### Can I add on to my existing pallet rack? ### How much does pallet rack cost? ### Do you install pallet rack? ## Carton Flow Rack by Service Area Delivery and installation across the Charlotte metro and nearby North and South Carolina communities. Charlotte: https://charlottepalletrack.com/service-area/charlotte/carton-flow-rack Concord: https://charlottepalletrack.com/service-area/concord/carton-flow-rack Gastonia: https://charlottepalletrack.com/service-area/gastonia/carton-flow-rack Huntersville: https://charlottepalletrack.com/service-area/huntersville/carton-flow-rack Mooresville: https://charlottepalletrack.com/service-area/mooresville/carton-flow-rack Matthews: https://charlottepalletrack.com/service-area/matthews/carton-flow-rack Monroe: https://charlottepalletrack.com/service-area/monroe/carton-flow-rack Pineville: https://charlottepalletrack.com/service-area/pineville/carton-flow-rack Indian Trail: https://charlottepalletrack.com/service-area/indian-trail/carton-flow-rack Kannapolis: https://charlottepalletrack.com/service-area/kannapolis/carton-flow-rack Statesville: https://charlottepalletrack.com/service-area/statesville/carton-flow-rack Hickory: https://charlottepalletrack.com/service-area/hickory/carton-flow-rack Salisbury: https://charlottepalletrack.com/service-area/salisbury/carton-flow-rack Rock Hill: https://charlottepalletrack.com/service-area/rock-hill/carton-flow-rack Fort Mill: https://charlottepalletrack.com/service-area/fort-mill/carton-flow-rack ## Other Rack Systems We Supply ### Pallet Rack Every pallet reachable, every time. The baseline we size everything else against. https://charlottepalletrack.com/products/pallet-rack ### Pushback Rack Two to six pallets deep from one aisle, without giving up much reach. https://charlottepalletrack.com/products/pushback-rack ### Pallet Flow Rack Load one side, pick the other, and let gravity enforce first in, first out. https://charlottepalletrack.com/products/pallet-flow-rack ### Drive-In Rack Deep reserve lanes with forklift entry for repeated pallets, trading individual access for fewer aisles. https://charlottepalletrack.com/products/drive-in-rack ### Cantilever Rack Arms with nothing in front of them, built for lumber, pipe, and anything a pallet can't hold. https://charlottepalletrack.com/products/cantilever-rack Moving buildings? Warehouse Relocation Services →: https://charlottepalletrack.com/warehouse-relocation ## Where We Work Located in Charlotte, NC, we serve the entire Charlotte metro with industrial pallet racks and warehouse storage solutions. ### Charlotte Pallet Rack #### Address 1515 Mockingbird Ln Ste 200A Charlotte, NC 28209 #### Phone (704) 480-3833 #### Business Hours Monday - Friday: 8:00 AM - 6:00 PM Saturday: Closed Sunday: Closed ## Ready to Price Carton Flow Rack? Call (704) 480-3833 or request a quote and we will start a layout. 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Pushback holds 2–6 pallets deep with LIFO by SKU; pallet flow suits FIFO or dated stock; drive-in suits bulk stock with few SKUs; cantilever supports long loads; carton flow serves case picking." } }, { "@type": "Question", "name": "Can I add on to my existing pallet rack?", "acceptedAnswer": { "@type": "Answer", "text": "Usually, if the connection matches and the existing configuration supports the added loads. Teardrop connections are not universal across manufacturers. Send a photo of the upright face, beam connector and any label so we can match new components to your system." } }, { "@type": "Question", "name": "How much does pallet rack cost?", "acceptedAnswer": { "@type": "Answer", "text": "Price depends on pallet positions, rack height, beam capacity, decking, freight and installation. Send pallet size, your heaviest load per level, clear height and building size for a free CAD layout and itemized quote. We supply new material only." } }, { "@type": "Question", "name": "Do you install pallet rack?", "acceptedAnswer": { "@type": "Answer", "text": "Yes. We handle design, supply of new rack material, and installation by experienced installation crews we schedule and manage. The rack is anchored to the floor, and the finished configuration has load plaques showing capacities." } } ] } ] ```