Rolling with Safety in Pallet Flow Rack - Forklift Pallet Separator | Mallard Manufacturing

Whether dealing with short loads, tall loads, or varying weights, effectively handling the formidable forces of gravity in your pallet flow rack requires meticulous design and the right product mix. Pallet separators stand out as crucial tools in harnessing these forces, ensuring a safe and efficient flow. A recent video test vividly demonstrates the ease of using the Forklift Separator to establish a pressure-free environment, promoting safer forklift extraction. Explore whether integrating a pallet separator could enhance the performance of your application.

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Pallet Flow Rack Forklift Separator Puts Safety to the Test

What is a Pallet Separator?

The pitch of a gravity flow lane creates the pallet movement, of course, but it also results in pressure applied to the front pallet from the rear pallets bearing down. Pallet separators hold back the rear pallets to isolate the front, thus eliminating those pressures. The front pallet is unencumbered without back pressure and can be removed more safely. Depending on the application, back pressure can be significant.

Calculate back pressure:
Combine total rear pallet weight (e.g., two 2000 pallets = 4000 lbs.)
Multiply the total combined weight by 6% (e.g., 4000 x .06 = 240 lbs.)
240 lbs of added back pressure is applied to the front pallet without the pallet separator.

It is important to note that the more pallets in the lane and the heavier the pallet loads… the higher the back pressure. Therefore, be sure to ask if a pallet separator would improve the safety and efficiency of your pallet flow rack before you settle on a design.

Mallard produces nine pallet separators for all flow rack lane variations, so there is a perfect match for your pallet flow rack solution. The forklift separator in this video test is uniquely designed for applications where forklifts remove pallets from the lane.

The Mallard Engineering Test Lab put this forklift separator to the test for a snack food manufacturing company needing a reliable gravity flow solution. With a variety of 16 customer-supplied pallets, the team thoroughly evaluated the pallets and the lane design to ensure optimal function. The results… lookin’ good! Take a look at the test.

Pallet Flow Test Lane Parameters:
3 Rails - 2.5” split-roller pallet flow
4” wheel centers
Pitch - ⅜” per foot

Accessories:
Forklift separator - FL301
Indirect mount speed controllers
Pallet Evaluation:
CHEP GMA-style pallets
Size - 40"w x 48"d x 50"t
Load weight - 1354 - 2250 lbs

Cautions:
Beware of broken boards
Remove dangling plastic wrap

Overall, the pallets were in good condition and flowed well in the system. Since there are only three bottom boards, the team tested the pallets in both orientations to confirm good contact with the rollers in both positions. While both directions performed well in the test, the pallets positioned with the stringers parallel to the rollers provided more contact with the flow lane, advancing the pallets at a slower speed.

When the stringers align parallel to the flow direction, it is referred to as the 'easy' or 'right' orientation. Conversely, positioning the stringers perpendicular to the flow direction is termed the 'hard' or 'wrong' orientation.

Optimizing Pallet Flow: Meticulous Design & Expert Support

All of these resources and expertise are available to you at Mallard. Contact Mallard's gravity flow experts for personalized design and testing support. Our team is dedicated to optimizing your warehouse solutions with innovative products and proven engineering expertise. Reach out today for a consultation that aligns with your unique needs and challenges.