Can a Matthews wholesale aisle combine narrow and broad cases?

Yes, using lane assignments and track support suited to each package family. Check handling space at the front as well as channel width, especially where broad cartons and order carts occupy the same working area.

How do we decide which products go near packing?

Use repeat order-line demand and the route from selection to consolidation. Place frequent picks where they reduce unnecessary movement, but preserve replenishment access and avoid grouping packages that make handling awkward.

Does FIFO apply to individual pieces in an open carton?

The lane sequences cartons, not the pieces inside each carton. Define the piece-picking and empty-box routine separately, and remove depleted containers so the next case can advance without confusing the assigned stock order.

Can future channels be added to a bay?

They may be added within a compatible, approved arrangement. Allow for the intended package range and supporting loads during planning, then check proposed inserts and divider changes before increasing forward stock.

Carton Flow Rack system inside a North Carolina warehouse

Matthews, North Carolina

Carton Flow Rack in Matthews, NC

Carton flow rack in Matthews can position repeat case picks closer to order consolidation while replenishment approaches from the opposite side. Inclined roller lanes keep the next carton available at the front, provided lane dimensions and supporting rack fit the packages and handling route.

The Monroe Road corridor and Sardis Road North serve wholesale, building-products, and specialty manufacturing activity near US-74. In a mixed operation, the picking area must accommodate small product cases without obstructing the larger packages and carts moving toward packing or dispatch.

(704) 480-3833

Carton flow rack procurement in a mixed warehouse

Order-picking speed gains come from fewer unnecessary journeys and more predictable stock presentation. They are not guaranteed by an increased lane count. Check whether the forward quantity lasts between refills and whether consolidation can accept orders at the rate the planned route produces them.

Matthews service belongs to a division of Warehouse Equipment & Supplies Co., supplying and installing since 1997. New-material quotations identify supporting bays, roller inserts, dividers, guides, stops, and managed installation tasks so the purchase can be judged as a complete working arrangement.

Keep full-pallet reserve requirements distinct from loose-case flow. Pallet flow uses gravity movement for complete loads and separate faces, whereas pushback serves reserve pallets from the same side. The replenishment plan must explain where reserve stock becomes cases and how it reaches the rear of the module.

Cart movement included in layout

Package clearance checked at removal

Complete insert scope identified

Call (704) 480-3833

Case flow rack between selection and consolidation

Front-face FIFO picking depends on back-of-lane restocking in the correct sequence. Give each replenishment channel a visible address and keep new receipts behind the existing units. If order rules distinguish dates or revisions, decide how those groups are separated before setting the lane count.

Carton flow rack channels carry cases and compatible totes on inclined roller tracks. Use loaded package trials to verify travel, front retention, and hand removal. Lightweight packs, heavy accessory cartons, and partly filled containers may require different track support despite looking similar on a product list.

Lane widths and dividers influence both alignment and selection space. A wider channel is not necessarily better if a narrow carton can turn across it. Measure the widest actual pack, check bowed sides and base seams, and allow the selected track system’s recommended working clearance.

Cart movement included in layout

Package clearance checked at removal

Complete insert scope identified

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

Matthews warehouse storage · Carton flow system options · Pallet flow reserve storage · Pushback reserve storage

Wholesale distribution

Building products

Light manufacturing

Laying out Matthews carton flow racking

A good module starts with a route drawing and ends with checked package assumptions.

Plot the order path

Trace movement from the forward pick face to consolidation and dispatch. Mark carts, tote transfer points, and where broad building-products packs need handling room so additional channels do not constrict the working aisle.

Select repeat picks

Review order-line frequency and refill quantities for the active assortment. Products used together may belong near one another, but package size and replenishment frequency still determine whether those positions are workable.

Assess insert compatibility

For conversion of pallet rack bays, record identification, beam openings, connections, and existing loads. Flow beds must fit a reviewed support arrangement while leaving enough vertical room for picking and rear refill handling.

Coordinate occupied work

We use experienced installation crews we schedule and manage within agreed work zones. Establish staging, unloading access, and a sequence that keeps the designated order-handling routes clear while selected bays are changed.

Recent Installations

Racking projects completed for warehouses across the Charlotte metro and nearby North and South Carolina communities.

View More Projects

Compare the Matthews picking options

Provide a floor sketch, order-line history, packed case dimensions, and rack bay details. The carton flow rack plan should state the proposed forward addresses and their connection to consolidation rather than showing storage positions alone. Discuss the layout at (704) 480-3833.