Practical warehouse storage management is fundamental to your business’s operational proficiency. Chaotic storage practices like leaving cartons or pallets on the floor lead to immense challenges. Such methods consume valuable space and create clutter that restricts visibility to items when they’re needed. Additionally, this disorganised handling prevents the functional use of your space’s height, compromising worker safety and product quality. Ultimately, this wastefulness can negatively impact service delivery and your bottom line.
Fortunately, solutions like long-span and carton flow racking present advanced ways to raise order-picking storage capacity and total productivity. So, let’s compare long-span vs. flow-racking systems by highlighting their distinct characteristics and real-world applications. Ultimately, we aim to equip you with the knowledge to optimise your inventory management procedures and drive your business forward by providing insights into these two powerful storage options.
Long-Span Racking Differences
Long-span racking is created to accommodate a wide selection of products, but mainly those that are larger or heavier than standard items. This highly versatile system features adjustable shelves that can be configured to suit different sizes and weights. With Krost, long-span racking can be paired with catwalk aisles to utilise vertical space fully.
Key Features of Long-Span Racking
Long-span racking provides unmatched adjustability. Shelves can be effortlessly repositioned to suit various product sizes. Also, items stored on its shelves can be reached easily, which improves picking efficiency. Lastly, long-span racks are built to withstand heavy loads because they are made from tough materials.
Applications of Long-Span Racking
Long-span racking is beneficial in environments where diverse product types are stored. It is normally used in retail warehouses to store bulk items or oversized products. It is also installed in manufacturing facilities to hold raw materials and components that vary in size. It is useful in distribution centres, where free access to a range of products is necessary.
Flow Racking Differences
Conversely, flow racking (or carton live racking) is designed for high-density storage and useful order picking of smaller items. This system employs a gravity-fed mechanism where cartons are placed on inclined shelves, allowing them to flow forward as items are picked from the front.
Key Features of Carton Live Racking
Krost’s flow racking has a gravity-fed design, which enables automatic stock replenishment as stock is picked. It also maximises vertical space usage, holding more products in less floor space. It is therefore high density. Lastly, it supports a First-In-First-Out (FIFO) inventory management practice, limiting the risk of obsolescence.
Read: Drive-Through vs. Carton Live Racking: FIFO Showdown for more information about FIFO inventory management
Applications of Flow Racking
Flow Racking is great for environments with high turnover rates of smaller items. General applications include e-commerce fulfilment centres, where prompt order processing is pivotal. It is also ideal for pharmaceutical warehouses to manage fast-moving items with expiration dates. Finally, it works well in food distribution centres because the stored stock is kept fresh through constant rotation.
Comparing Long-Span and Carton Flow Racking
Multiple factors must be considered when deciding between long-span and flow-racking systems, including:
| Feature | Long-Span Racking | Carton Flow Racking |
| Best For | Larger, heavier items | Smaller, fast-moving items |
| Accessibility | Easy entry from all sides | Front access only |
| Storage Density | Moderate | High |
| Replenishment Method | Manual replenishment | Automatic replenishment |
| Inventory Management Style | Flexible (varied sizes) | FIFO (First-In-First-Out) |
Real-Life Case Studies
Many companies have successfully implemented these racking systems to elevate their operations:
E-commerce Giant (Carton Flow):
A well-known e-commerce company adopted flow racking in its fulfilment centres to simplify order-picking methodologies. The result was a 30% increase in picking speed due to the gravity-based structure facilitating easier entry to regularly ordered items.
Retail Warehouse (Long-Span):
A large retail warehouse utilised long-span racking to manage its seasonal inventory better. The warehouse improved its picking efficiency by 25%, promoting faster restocking during peak shopping periods by adjusting shelf heights based on seasonal demand.
Pharmaceutical Distributor (Carton Flow):
A pharmaceutical distributor implemented a carton live system to manage its inventory of medications with varying expiration dates. This strategy both improved picking accuracy and lowered waste due to expired products by 15%.
Conclusion
Comparing long-span and flow-racking systems is worthwhile when you are familiar with your specific storage needs and goals. Long-span racking offers flexibility for larger items and varied inventory types, while pallet flow racking is efficient in environments requiring high density and quick turnover of smaller products. Knowing each system’s unique features and applications supports constructive decision-making and maximises the performance of your storage facility.
If you speak to one of our specialists today, you’ll get closer to creating a streamlined process that supports your business objectives. Installing the right system will pave the way for order-picking storage and operational improvement, whether you opt for long-span or flow-racking.
