Pallet Flow Rack in the Lehigh Valley

Engineered lane depths run 2 to 20 pallets. Most Lehigh Valley food and pharma installations land between 8 and 15 deep, sized to match typical pre-shipment staging volume per SKU. Depths beyond 15 require strict attention to pallet-quality consistency — a single bent stringer can jam the lane and require a retrieval operation.

GMA-grade 4-way pallets in solid condition are the baseline. Damaged stringers, splintered leading edges, or warped decks will hang up on rollers or skate wheels and cause jams. If you cannot guarantee GMA-grade quality across your inventory, pushback or selective is more forgiving.

Technically yes, but FIFO picks in the order pallets were loaded — so mixing SKUs defeats the main advantage. Most flow installations run one SKU per lane, with lane depth sized to equal typical pre-shipment volume for that SKU.

Brake rollers limit free-flow speed to roughly one foot per second. Every 4 to 8 feet of lane depth adds another brake. A loaded pallet rolls from back to front in a 15-deep lane in roughly 15 to 30 seconds — predictable, slow enough for safety, fast enough for operations.

Drive-in delivers similar or greater density at roughly half the capital cost, but it rotates LIFO only and exposes the rack to forklift-entry damage. Pallet flow costs more and demands better pallet quality, but enforces FIFO automatically, eliminates in-rack forklift traffic, and separates load and pick aisles. The decision almost always comes down to whether the product requires FIFO.

Pallet flow is the highest capital cost per position of the major rack types, but the ROI is in labor and compliance. Eliminating manual FIFO enforcement, cutting forklift travel 40–60% with separate aisles, and avoiding expired-inventory write-offs typically produces a 24 to 48 month payback for Lehigh Valley cold-chain and pharmaceutical distributors.

Pallet flow typically runs $200–$400 per pallet position installed — the highest of the common rack types, driven by the roller lanes and braking systems. It earns that back in FIFO compliance and labor savings for date-sensitive product. Lehigh Valley Pallet Racking specs lane depth and roller type to your pallet quality before quoting, so the price reflects your actual freight.