Carton flow racking: optimise picking efficiency and storage space

In an increasingly demanding logistics environment, companies must address major challenges: optimising storage space, improving workflows, reducing picking times and enhancing workstation ergonomics.

To meet these objectives, PRODEX, a company of the MAVENTIS Group, develops high-performance dynamic carton racking solutions, also known as carton flow storage systems.

These systems optimise warehouse organisation while improving operator productivity and safety.

What is carton flow racking?

Dynamic carton racking is a storage system based on the principle of gravity. It consists of racking structures (medium-duty or heavy-duty) equipped with inclined roller tracks, allowing cartons to move automatically from the loading point to the picking area.

This system operates according to two main principles:

  • FIFO (First In, First Out): ideal for fast-moving or perishable products,
  • LIFO (Last In, First Out): suited to specific logistics constraints.

Thanks to this system, operators always pick products from the front, without having to move unnecessarily through the aisles.

A solution designed to optimise order picking

One of the main advantages of PRODEX dynamic carton racking lies in its ability to significantly improve order picking operations.

Reduced operator movement

Products automatically move towards the picking area. As a result:

  • less movement,
  • reduced processing time
  • reduced operator fatigue.

Increase in the number of stored items

The system enables for more items to be stored in the same space by optimising storage depth and height.

Improved productivity

Picking becomes faster, smoother, and more reliable, which directly impacts the warehouse’s overall performance.

Maximising storage space

Dynamic carton racking reduces the number of aisles needed by enabling for storage in the back of the rack.

By eliminating certain traffic zones, you gain:

  • in terms of usable floor space,
  • in terms of storage density,
  • in product visibility.

Cette organisation améliore également la lisibilité des flux logistiques et limite les erreurs de picking.

Ergonomics and safety at the heart of the system

PRODEX dynamic storage solutions are designed to improve working conditions for operators.

Optimized ergonomics

  • Direct access to products,
  • Appropriate picking height,
  • Reduction of strenuous repetitive movements.

Reduction in musculoskeletal disorders

Less walking, less heavy lifting → fewer musculoskeletal disorders.

Enhanced security

  • Better organization of work areas,
  • Less vehicle traffic,
  • Reduced risk of accidents.

Flexible and customisable solutions

PRODEX live-storage racking for cartons is suitable for all warehouse layouts:

  • Integration into existing medium- or heavy-duty racking,
  • Installation on single- or double-sided pallet racks,
  • Compatibility with various types of boxes and loads.

Available options:

  • Free-running or motorized roller conveyors,
  • Suitable materials: PVC, steel, stainless steel,
  • Angles adjusted according to the loads,
  • Safety stops and reference dividers.

This modularity allows us to design fully customised systems that are perfectly tailored to your logistics processes.

Tangible benefits for your logistics performance

Installing a dynamic carton storage system delivers measurable benefits in several areas:

Operational performance

  • Faster order fulfillment,
  • Reduced processing times,
  • Optimisation of internal workflows.

Improved inventory management

  • Controlled inventory turnover (FIFO/LIFO),
  • Improved traceability,
  • Reduction in picking errors.

Economic profitability

  • Maximising space without expanding,
  • Reduction in labor costs,
  • Improvement in overall performance.

Applications across a wide range of industries

Dynamic carton racking is commonly used in:

  • Logistics and e-commerce,
  • Manufacturing industry,
  • Retail and mass retail,
  • Pharmaceutical and medical,
  • Automobiles and auto parts.

Wherever fast and accurate picking is a priority, this solution sets the standard for performance.

PRODEX, an expert in logistics planning

With over 70 years of expertise, PRODEX helps companies design customised industrial storage and logistics solutions.

Our teams offer you:

  • A comprehensive analysis of your data streams,
  • A customised assessment of your warehouse,
  • A solution tailored to your operational needs,
  • Support from design through installation.

Would you like to optimise your warehouse?

PRODEX live-storage racking for cartons is the ideal solution for boosting your productivity, ensuring safe operations, and optimising your storage space.

Contact our team for a personalised offer:
contact@prodex-online.com