Carton flow is a form of shelving that uses a gravity feed rear-load design. Each unit consists of one or more inclined runways. Merchandise is loaded in the rear of each runway. As an item is removed from the front, the item directly behind it slides forward in place of the previous.
The main advantage of carton flow rack over static rack or shelving systems is that merchandise remains better organized and easier to find or pick. With carton flow rack, the product is automatically rotated on a first-in, first-out basis. Merchandise is stocked in the rear of the carton flow rack and moves toward the picking station in front on an inclined shelf equipped with specially designed roller track. When a carton is removed from the picking station, the next one in line rolls to the front. Carton flow always keeps items within reach. Inventory is easier to monitor and control since products are fully visible at all times. A limitation worth mentioning is that carton flows are not well suited for larger volume or full case applications.
Restocking and picking typically offer the greatest opportunity for improving efficiency within order-picking operations. With carton flow rack systems, labor savings of up to 75% can be realized almost immediately. Because items are picked from the front and stocked from the rear, both functions can be performed without interference and with minimized travel.
In a static storage system such as standard shelving, stockers and pickers often do a lot of unnecessary travel.

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