Carton Flow Rack Systems in Baltimore, MD
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Gravity-fed case-pick rack — rear-loaded, front-picked, pick-to-light ready, 2–3× the pick velocity of static shelving.
About Carton Flow Rack
Carton flow rack is a gravity-fed dynamic storage system built for case and carton picking — not full pallets. Cases are loaded from the rear onto inclined roller or skate-wheel tracks and flow forward automatically to a pick face presented at ergonomic waist height. As a picker pulls a carton, the next one rolls into place. Because replenishment happens from the opposite side of the rack, pick operations never pause for restocking — a structural advantage that delivers 2 to 3 times the pick velocity of static shelving for the same operator. Carton flow is the default front-line pick medium for Baltimore-area e-commerce fulfillment at BWI and Sparrows Point, the Under Armour Port Covington apparel operations, auto parts distribution, and regional pharmaceutical case-pick. Baltimore Pallet Rack designs and installs carton flow systems integrated with pick-to-light, WMS zones, and takeaway conveyor throughout the Baltimore metro.
How Carton Flow Rack Works
The mechanics behind the system — and why they matter for your operation.
Rear replenishment
A replenishment operator loads cases onto the rear of the inclined track from a dedicated restock aisle — typically while pickers are actively working the front face on the other side.
Gravity-fed flow
Cases roll forward on steel rollers or plastic skate wheels pitched 3 to 5 percent. A front lip stops the leading case at the pick face, held in position and ready to pick.
Ergonomic pick face
Tracks are typically set at waist height (40–54 inches) in the main pick zone, with secondary levels above and below. Pickers never reach above shoulder or below the knee in the fast-moving zones.
Integrated with pick logic
Carton flow bays are the native home of pick-to-light and put-to-light indicators, WMS pick zones, and carousel-fed takeaway conveyor downstream. The whole pick line is typically designed around the flow face.
When to Choose Carton Flow Rack
- • You pick cases, cartons, or totes — not full pallets — at a high per-picker velocity
- • Replenishment disruption is a measurable cost (pickers waiting for restock)
- • You run pick-to-light, put-to-light, or WMS zone-based picking
- • SKU count is in the hundreds-to-thousands in a zone with high velocity variance
- • Ergonomic risk on static shelving is driving workers' comp claims
When Not to Choose
- • You pick full pallets — use pallet rack instead
- • Your SKU count is small and static shelving is already fast enough
- • Case weight routinely exceeds 100 lbs — check heavy-duty track spec or alternative
- • Your budget targets the lowest-cost shelving and pick velocity is not a constraint
Specifications at a Glance
- Tier configuration
- 3 to 5 tiers typical, 18–36" bay height
- Bay width
- 3 to 10 feet
- Track type
- Full-width steel rollers or plastic/metal skate wheels
- Track pitch
- 3–5% (gravity-feed)
- Carton capacity
- 50–100 lbs per case (typical); up to 250 lbs on heavy-duty tracks
- Pick-face height
- Primary zone typically set at 40–54" for ergonomics
- Replenishment
- From the opposite side of the rack — zero pick disruption
- Integration
- Pick-to-light, put-to-light, WMS zones, takeaway conveyor
- Upright style
- Roll-formed teardrop or structural-channel, carton-flow specific
- Code compliance
- IBC 2021 (Maryland amendments), RMI ANSI MH16.1-2023
Carton Flow vs. Other Case-Pick Storage Media
| Attribute | Static Shelving | Carton Flow | AS/RS Shuttle |
|---|---|---|---|
| Picks/hour per operator | Baseline (1×) | 2–3× | 4–8× |
| SKU density per sq ft | Medium | High | Highest |
| Replenishment disruption | Pickers pause for restock | Zero (rear-load while picking) | Fully automated |
| Ergonomic strain | High (reach, stoop) | Low (waist-height face) | None (goods-to-person) |
| Pick-to-light integration | Retrofit | Native | Native |
| Install time | 1–3 days | 1–2 weeks | 3–6 months |
| Best SKU velocity | Low-medium | Medium-high | High-very high |
| Relative capital cost / SKU | $ | $$ | $$$$$ |
Where Carton Flow Rack Fits in the Baltimore Metro
Specific industries across Baltimore and Maryland where this system pays off.
E-commerce fulfillment — BWI corridor, Sparrows Point, White Marsh
Amazon Sparrows Point (Tradepoint Atlantic), Amazon BWI fulfillment, and the 3PL fulfillment centers ringing BWI airport use carton flow as the main pick-face medium for small-parcel order picking. Rear replenishment lets the pick wave run uninterrupted during peak.
Apparel & retail DC — Port Covington, Rocky Point, Hanover
Under Armour (Port Covington HQ), TJX regional operations (Rocky Point), and Hanover-corridor apparel DCs run carton flow in seasonal fashion pick lines where SKU turnover is high and static shelving cannot sustain replenishment cadence.
Auto parts distribution — Beltsville, Rosedale, White Marsh
NAPA Eastern region operations, O'Reilly Auto Parts, and AutoZone regional DCs use carton flow for the middle SKU tier — fast movers on the pick face, slower SKUs on adjacent static shelving.
Pharmaceutical case-pick — Hunt Valley, Cockeysville, Elkton
Becton Dickinson regional operations, McCormick spice case-pick zones, and Elkton-area specialty operations use carton flow for fast-moving SKUs in their case-pick zones, paired with pick-to-light for lot-level accuracy requirements.
Foodservice & grocery case-pick — Jessup, Halethorpe, Glen Burnie
Sysco Baltimore (Jessup) case-pick zones and regional grocery case-pick operations use carton flow for high-velocity shelf-stable SKUs where full pallet picking does not make sense but static shelving can't keep up.
Product Features
- 3 to 5 tier configurations with 18–36" bay heights
- Full-width steel roller or skate-wheel track options
- Ergonomic pick-face height tuning in the primary zone
- Rear replenishment aisle — zero pick-face disruption
- Pick-to-light, put-to-light, and WMS zone integration ready
- Compatible with takeaway conveyor and sortation integration
- Engineered to IBC 2021 (Maryland amendments) and RMI ANSI MH16.1-2023
Benefits for Your Business
Frequently Asked Questions
Real answers for buyers researching carton flow rack in the Baltimore metro area.
What weight can a carton flow track handle?
Does carton flow require pick-to-light?
Can carton flow handle bagged or irregular cartons?
How much replenishment aisle do I need?
Can I mix carton flow with pallet rack?
What does a typical Baltimore carton flow install cost?
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