How to Create Flue Space in Deep-Lane Pallet Flow Rack | Mallard Manufacturing

In some cases, deep lane designs require a flue space between the pallets. The flue space is necessary for fire safety, to allow overhead sprinklers to distribute water effectively to the lower rack levels. This requirement is becoming more common in pallet flow rack to receive fire and or insurance sign-offs. Wherever is driving your flue space need, we have the team to show you how it’s done… we’ll even test it for you before you finalize your order to ensure we’ve got it right.

Take a look at a recent flue space test on a deep-lane system for a global chemicals company. Gravity flow tests are completed in our Engineering Testing Center as a courtesy to our customers.

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Equipping Deep-Lane Pallet Flow Rack to Satisfy Safety Compliance

Pallet flow rack can fulfill a variety of industrial applications, from high-volume case picking to mixed-SKU pallet building, but it is most commonly considered for high-density pallet storage. Pallet flow systems consolidate inventory into deep, multi-level SKU lanes with a pitched design that automatically feeds pallets from a load aisle to the opposite pick aisle. Stock is always at the ready, search times are reduced, and pick accuracy rates are boosted with pallet flow rack. However, while using a pallet flow system is relatively easy, the design of your system takes careful consideration to ensure safe operation and compliance with fire, building, and insurance regulations.

Pallet Flow Lane Overview:
Wheeled pallet flow - 2 rails
Lane depth - 8 pallets
Lane width - 32” out-to-out
Drop-in speed controllers at 48” intervals
Pitch - 7/16” per foot
Forklift separators - 2 per lane

Pallet Specs:
32” x 40” wooden pallets
Features: 2 runners 5.5” wide
Load weight 1650 - 2000 lbs.
Pallet orientation - the Hard Way
Condition - good quality pallets, 2 of 8 have protruding nails and splintered boards not recommended for use

The first thing you may notice is two Forklift Separators popping up from the flow lane. The forklift separators will create the two 12” gaps between pallets required for compliance. Two are needed due to the significant lane depth.

The forklift separator automatically separates pallets. It is most often used at the forward pallet position to isolate the front pallet and remove the pressure of the rear pallets, resulting from the pitched lane design. With the pallet isolated, it is easier and safer to remove from the lane.

However, in this application, the first separator is in the second position, creating a gap between pallets 2 and 3. The second forklift separator is in the sixth position, separating pallets 6 and 7.

As the front pallet is extracted from the lane, the second pallet flows to the pick face, releasing the separator and, thus, the rear pallets. Once the sixth pallet flows past separator #2, it releases, and pallets 7 and 8 flow. As the pallet separators are once again filled with pallets, they automatically stop and hold subsequent pallets.

Completing a Safe Pallet Flow Lane Design

In addition to the forklift separators, drop-in speed controllers are used in pairs to help control flow speed and tracking of the pallets. Drop-in controllers make direct contact with the bottom of the pallets, which works well with these wooden pallets and the ample-width runners.

The customer-supplied pallets are smaller than standard GMA-style pallets (32” x 40” vs. 40” x 48”), so you may note that the lane only requires two rails of wheels to support the load vs. three typically used with wider pallets. The wood pallets were generally in good condition, which is necessary to prevent pallet hang-ups, slowdowns, and possibly repairs to your rack system.

By orienting the pallets the “hard” or “wrong” way (pallet stringers run perpendicular to the direction of flow) you can narrow the lane width to the 32” wide design and maximize space.

Contact the Mallard gravity flow rack experts for design support for all your pallet flow, carton flow and gravity conveyor needs. Don’t forget to request a test! Visit our Resources page for product information, spec sheets, RFQs, and testing request forms --or just give us a call today!