--- title: "Carton Flow Rack in Louisville, KY | Free Layout & Quote" url: https://louisvillepalletracks.com/products/carton-flow-rack description: "Carton flow rack and shelving for case picking in Louisville. Wheel beds sized to your cartons, restocked from the back aisle. Call (502) 521-1485." lang: en --- Image: Carton Flow Rack system in an industrial warehouse (https://louisvillepalletracks.com/assets/carton-flow-hero-y0vnsglk.jpg) # Carton Flow Rack Systems in Greater Louisville Carton flow rack is built for the picker, not the pallet. Cases sit on inclined wheel beds, so every time a picker takes one, the next slides forward to the exact same spot - no reaching, no re-facing product, no walking to find the case that should be there. Restocking happens from a separate back aisle, so replenishment never interrupts the pick line. It's the right system when picking is by the case or the each, not the pallet, and when enough SKUs need a dedicated face that static shelving turns into a maintenance problem. Most warehouses run it in the lower levels of a bay with reserve pallets stacked above, so one footprint handles both active picking and overflow storage. We size wheel beds and lane widths to your case dimensions, pick rate, and SKU count, and show where the fastest movers should sit in the bay. (502) 521-1485 ## 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://louisvillepalletracks.com/assets/carton-flow-rack-DfuFYV4P.jpg) Image: Carton flow shelving in use on a warehouse pick line (https://louisvillepalletracks.com/assets/carton-flow-hero-y0vnsglk.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 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. 1 Phone consultation 2 CAD layout 3 Itemized quote 4 Delivery & installation ## Recent Installations A sample of racking projects completed across the region. Image: Carton flow rack lanes installed beneath pallet rack bays (https://louisvillepalletracks.com/__l5e/assets-v1/862c0f55-579a-45db-b7d0-8b28ca7ab40a/carton-flow-racking.jpg) Image: Drive-in pallet rack system installed in a warehouse (https://louisvillepalletracks.com/__l5e/assets-v1/6bb0553b-4f16-4d86-89a7-ba20efd69034/drive-in.jpg) Image: Tall selective pallet rack rows with wire decking (https://louisvillepalletracks.com/__l5e/assets-v1/61c53cf9-cea8-4d8f-a20e-f5d45ea229bd/igt-6.jpg) Image: Selective pallet rack aisle with wire decking in a distribution center (https://louisvillepalletracks.com/__l5e/assets-v1/83ef5124-a97e-4c86-b417-f6204e5563d1/img-1220.jpg) Image: New pallet rack rows installed in an open warehouse (https://louisvillepalletracks.com/__l5e/assets-v1/1f1f2ec7-76a6-4e1a-a7bc-6162b6d05133/img-5455.jpg) Image: Green and orange selective pallet rack rows along a warehouse wall (https://louisvillepalletracks.com/__l5e/assets-v1/2fcd6b62-b063-4601-8ee6-05e065cad952/medco-cleveland-5.jpg) Image: Multiple rows of selective pallet rack with wire decking (https://louisvillepalletracks.com/__l5e/assets-v1/6cdb19e3-61c0-4b2e-8aac-e8a7ca4ab8d2/photo-aug-03-6-17-41-pm.jpg) Image: Pallet rack rows installed across a warehouse floor (https://louisvillepalletracks.com/__l5e/assets-v1/e26859a0-123d-4abb-bbc9-77e49a92c8af/photo-jul-22-6-45-56-pm.jpg) Image: Cantilever rack columns with orange arms installed against a wall (https://louisvillepalletracks.com/__l5e/assets-v1/59190071-06d9-4416-984d-7f1193cf9c9a/photo-may-15-2026-7-28-50-pm-1.jpg) Image: Push back pallet rack carts and rails in a cold storage room (https://louisvillepalletracks.com/__l5e/assets-v1/18d53e90-bd8d-4c09-8c81-e1bdd5106ecb/udf-pushback-rack.jpg) View More Projects: https://louisvillepalletracks.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 (502) 521-1485. ### What's Included: - Free warehouse consultation - CAD layout drawings - Itemized project quote - Rack type recommendations - Installation timeline ## Carton Flow Rack Questions We Hear Most ### How much pallet storage will my layout hold? ### How long does it take to get and install pallet rack? ### What determines the price of a pallet rack system? ### How do I choose between rack types? ### Can I add on to my existing pallet rack? ## Carton Flow Rack by Service Area Delivery and installation across Greater Louisville and Southern Indiana. Louisville: https://louisvillepalletracks.com/service-area/louisville/carton-flow-rack Jeffersontown: https://louisvillepalletracks.com/service-area/jeffersontown/carton-flow-rack Shepherdsville: https://louisvillepalletracks.com/service-area/shepherdsville/carton-flow-rack Elizabethtown: https://louisvillepalletracks.com/service-area/elizabethtown/carton-flow-rack Shelbyville: https://louisvillepalletracks.com/service-area/shelbyville/carton-flow-rack Frankfort: https://louisvillepalletracks.com/service-area/frankfort/carton-flow-rack Bardstown: https://louisvillepalletracks.com/service-area/bardstown/carton-flow-rack La Grange: https://louisvillepalletracks.com/service-area/la-grange/carton-flow-rack New Albany: https://louisvillepalletracks.com/service-area/new-albany/carton-flow-rack Clarksville: https://louisvillepalletracks.com/service-area/clarksville/carton-flow-rack Jeffersonville: https://louisvillepalletracks.com/service-area/jeffersonville/carton-flow-rack Mt. Washington: https://louisvillepalletracks.com/service-area/mt-washington/carton-flow-rack Radcliff: https://louisvillepalletracks.com/service-area/radcliff/carton-flow-rack Georgetown: https://louisvillepalletracks.com/service-area/georgetown/carton-flow-rack Brooks: https://louisvillepalletracks.com/service-area/brooks/carton-flow-rack ## Other Rack Systems We Supply ### Pallet Rack Every pallet reachable, every time. The baseline we size everything else against. https://louisvillepalletracks.com/products/pallet-rack ### Pushback Rack Two to six pallets deep from one aisle, without giving up much reach. https://louisvillepalletracks.com/products/pushback-rack ### Pallet Flow Rack Load one side, pick the other, and let gravity enforce first in, first out. https://louisvillepalletracks.com/products/pallet-flow-rack ### Drive-In Rack No aisles. The forklift enters the structure, and the floor holds more pallets per square foot than any other system. https://louisvillepalletracks.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://louisvillepalletracks.com/products/cantilever-rack ## Where We Work Located in Louisville, we serve the entire Greater Louisville region with industrial pallet racks and warehouse storage solutions. ### Louisville Pallet Racks #### Address 6844 Bardstown Rd. Unit #2687 Louisville, KY 40291 #### Phone (502) 521-1485 #### Business Hours Monday - Friday: 8:00 AM - 6:00 PM Saturday: Closed Sunday: Closed ## Ready to Price Carton Flow Rack? Call (502) 521-1485 or request a quote and we will start a layout. 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