Streamline Distribution - Try Pallet Flow Rack for Depalletizing Efficiency | Mallard Manufacturing

Video Test Puts It All Together for Leading Grocery Chain
A recent customer test in our in-house testing lab shows how a pallet flow functions with the Ergo Cell pallet separator and optional lift table. This test examines different pallet load heights, weights, and pallets to simulate the challenges at the customer’s distribution facilities. It also explores how effective (or not) stacking pallets is in this depalletizing application. Take a look!
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Building the Case for Depalletizing with Pallet Flow Rack
In the fast-paced world of grocery distribution, efficiency is paramount. A reliable depalletizing solution can significantly streamline operations, reducing bottlenecks and ensuring timely delivery of goods to shelves. However, manual depalletizing is labor-intensive and physically demanding, posing challenges to operational efficiency. This is where pallet flow rack shines --it streamlines workflow and minimizes worker strain, making it an ideal choice for grocery distribution facilities aiming to boost productivity and reduce operational costs.
Pallet flow rack is a gravity-fed conveyance system that uses wheels or rollers to flow materials from a load side to an opposite extraction side of the lane. Depending on your application, you can design your pallet flow lanes to positively support ergonomic positioning, helping to speed up depalletizing activities while minimizing injuries and related operational expenses. Pallet flow offers a number of additional benefits, including:
Depalletizing Advantages with Pallet Flow Rack
Increase throughput - continuous workflow with a steady stream of pallets in the lane.
Ensure easy carton access - unit loads are accessible from multiple pallet sides, offering valuable flexibility for mixing centers.
Create safe workspaces - isolate workers from the forklifts delivering cargo since pallet flow loads and picks from opposite aisles.
Reduce worker strain - incorporate industrial lift tables, allowing height adjustment for ideal ergonomic positioning.
There are two mounting options for your gravity flow lanes: flush-mounted or pitched. The best design depends on your application.
Relieve the Pressure with the Ergo Cell Separator
In a pitched pallet flow lane, the rear pallets will bear down on the front pallet, placing additional pressure on that pallet. The Ergo Cell is a pneumatically triggered hold-back device that isolates the front pallet from the rear pallets in the lane. This separation makes picking up and removing empty pallets from the lane easier, reducing work strain. It also provides easier access to cases at the back of the pallet from the side of the lane if necessary. The Ergo Cell is triggered by a wireless controller or a mounted control box near the lane, giving the worker control over releasing the rear pallets to flow forward.
Hydraulic Lift Tables Take It Up a Notch
If desired, you can add a hydraulic lift table to support better ergonomic positioning for workers and further reduce the physical strain of lifting cases and empty pallets. The lift table is operated by a foot pedal, giving the worker control over raising or lowering the table and the height. Pallets on the lift table can be turned 360° to reach cartons in the rear of the pallet without straining.
Positive Test Results -- This Design is a Go
The lane test yielded positive results for this customer, with the drop-in speed controllers effectively regulating pallet movement. However, our team advises ensuring pallet stacks are stable before loading. For this application, we do not recommend double-stacking pallets to enhance worker safety and protect product integrity. The Ergo Cell pneumatic cylinders facilitate precise pallet indexing while restraining rear pallets within the lane, allowing seamless pallet unloading without hindrance from adjacent pallets.
As part of our in-house testing at Mallard, we conduct thorough pallet reviews to identify potential risks associated with pallet condition or materials. Various concerns were noted, including broken or cracked bottom boards, protruding nails, and warping, all of which can affect flow efficiency. The team also cautions against loose or dangling plastic wrap that may interfere with wheels and disrupt pallet movement.
Build Your Depalletizing Solution with Pallet Flow Rack
The Mallard gravity flow experts are available to help you optimize your depalletizing activities. Contact our team today for a solution that improves your process, maximizes your space, and protects your team from unnecessary strain and injuries.